Aerosol delivery system

ABSTRACT

An aerosol delivery system has a fluid-transfer article with a first region for holding an aerosol precursor and a second region to which the aerosol precursor is transferred from the first region. The second region includes an activation surface which interacts thermally with a heater of the aerosol delivery system to form an aerosol from said aerosol precursor. When the user sucks or inhales through the aerosol delivery system, the diaphragm flexes to open an air-flow pathway between the activation surface and the heater, so that aerosol passes from the heater to the user in the airflow. When the user ceases to suck or inhale, the flexible diaphragm flexes to close the air-flow pathway and reduce escape of aerosol precursor from the second part of the fluid-transfer article.

CROSS REFERENCE TO RELATED APPLICATIONS/INCORPORATION BY REFERENCE STATEMENT

This application is a non-provisional application claiming benefit to the international application no. PCT/EP2020/057345 filed on Mar. 17, 2020, which claims priority to EP 19164423.6 filed on Mar. 21, 2019. This application also claims benefit to the international application no. PCT/EP2020/057347 filed on Mar. 17, 2020, which claims priority to EP 19164404.6 filed on Mar. 21, 2019, and to EP 19164429.3 filed on Mar. 21, 2019, and to EP 19164431.9 filed on Mar. 21, 2019. This application also claims benefit to the international application no. PCT/EP2020/057351 filed on Mar. 17, 2020, which claims priority to EP 19164425.1 filed on Mar. 21, 2019. This application also claims benefit to the international application no. PCT/EP2020/057346 filed on Mar. 17, 2020, which claims priority to EP 19164420.2 filed on Mar. 21, 2019. This application also claims benefit to the international application no. PCT/EP2020/057336 filed on Mar. 17, 2020, which claims priority to EP 19164467.3 filed on Mar. 21, 2019. This application also claims benefit to the international application no. PCT/EP2020/057338 filed on Mar. 17, 2020, which claims priority to EP 19164470.7 filed on Mar. 21, 2019. This application also claims benefit to the international application no. PCT/EP2020/057294 filed on Mar. 17, 2020, which claims priority to EP 19164463.2 filed on Mar. 21, 2019, and to EP 19164430.1 filed on Mar. 21, 2019.

FIELD OF THE DISCLOSURE

The present disclosure relates to an aerosol delivery system, an aerosol-generation apparatus, and a fluid-transfer article for an aerosol delivery system. The present disclosure preferably relates to an aerosol delivery system including a heater configured to heat an aerosol precursor to generate an aerosolized composition for inhalation by a user, and to an aerosol-generation apparatus and a fluid-transfer article therefor.

BACKGROUND

A smoking-substitute device or system is an electronic device that permits the user to simulate the act of smoking by producing an aerosol mist or vapor that is drawn into the lungs through the mouth and then exhaled. The inhaled aerosol mist or vapor typically bears nicotine and/or other flavorings without the odor and health risks associated with traditional smoking and tobacco products. In use, the user experiences a similar satisfaction and physical sensation to those experienced from a traditional smoking or tobacco product and exhales an aerosol mist or vapor of similar appearance to the smoke exhaled when using such traditional smoking or tobacco products.

One approach for a smoking substitute device is the so-called “vaping” approach, in which a vaporizable liquid, typically referred to (and referred to herein) as “e-liquid”, is heated by a heater to produce an aerosol vapor which is inhaled by a user. The e-liquid typically includes a base liquid as well as nicotine and/or flavorings. The resulting vapor therefore also typically contains nicotine and/or flavorings. The base liquid may include propylene glycol and/or vegetable glycerin.

A typical vaping smoking substitute device includes a mouthpiece, a power source (typically a battery), a tank for containing e-liquid, as well as a heater. In use, electrical energy is supplied from the power source to the heater, which heats the e-liquid to produce an aerosol (or “vapor”) which is inhaled by a user through the mouthpiece.

Vaping smoking substitute devices can be configured in a variety of ways. For example, there are “closed system” vaping smoking substitute devices, which typically have a sealed tank and heating element. The tank is pre-filled with e liquid and is not intended to be refilled by an end user. One subset of closed system vaping smoking substitute devices include a main body which includes the power source, wherein the main body is configured to be physically and electrically coupled to a consumable including the tank and the heater. The consumable may also be referred to as a cartomizer. In this way, when the tank of a consumable has been emptied, that consumable is disposed of. The main body can be reused by connecting it to a new, replacement, consumable. Another subset of closed system vaping smoking substitute devices are completely disposable and intended for one-use only. There are also “open system” vaping smoking substitute devices which typically have a tank that is configured to be refilled by a user. In this way the device can be used multiple times.

An example vaping smoking substitute device is the Myblu™ e-cigarette. The Myblu™ e cigarette is a closed system device which includes a main body and a consumable. The main body and consumable are physically and electrically coupled together by pushing the consumable into the main body. The main body includes a rechargeable battery. The consumable includes a mouthpiece, a sealed tank which contains e-liquid (also referred to as an aerosol precursor), as well as a heater, which for this device is a heating filament coiled around a portion of a wick. The wick is partially immersed in the e-liquid and conveys e-liquid from the tank to the heating filament. The device is activated when a microprocessor on board the main body detects a user inhaling through the mouthpiece. When the device is activated, electrical energy is supplied from the power source to the heater, which heats e-liquid from the tank to produce a vapor which is inhaled by a user through the mouthpiece.

For a smoking substitute device, it is desirable to deliver nicotine into the user's lungs, where it can be absorbed into the bloodstream. As explained above, in the so-called “vaping” approach, “e-liquid” is heated by a heating device to produce an aerosol vapor which is inhaled by a user. Many e-cigarettes also deliver flavor to the user, to enhance the experience. Flavor compounds are contained in the e-liquid that is heated. Heating of the flavor compounds may be undesirable as the flavor compounds are inhaled into the user's lungs. Toxicology restrictions are placed on the amount of flavor that can be contained in the e-liquid. This can result in some e-liquid flavors delivering a weak and underwhelming taste sensation to consumers in the pursuit of safety.

In aerosol delivery devices of the types noted above, it is desirable to avoid large liquid droplets reaching a user's mouth.

Pharmaceutical medicament, physiologically active substances and flavorings for example may be delivered to the human body by inhalation through the mouth and/or nose. Such material or substances may be delivered directly to the mucosa or mucous membrane lining the nasal and oral passages and/or the pulmonary system. For example, nicotine is consumed for therapeutic or recreational purposes and may be delivered to the body in a number of ways. Nicotine replacement therapies are aimed at people who wish to stop smoking and overcome their dependence on nicotine. Nicotine is delivered to the body in the form of aerosol delivery devices and systems, also known as smoking-substitute devices or nicotine delivery devices. Such devices may be non-powered or powered.

Devices or systems that are non-powered may comprise nicotine replacement therapy devices such as “inhalators”, e.g., Nicorette® Inhalator. These generally have the appearance of a plastic cigarette and are used by people who crave the behavior associated with consumption of combustible tobacco—the so-called hand-to-mouth aspect—of smoking tobacco. Inhalators generally allow nicotine-containing aerosol to be inhaled through an elongate tube in which a container containing a nicotine carrier, for example, a substrate, is located. An air stream caused by suction through the tube by the user carries nicotine vapors into the lungs of the user to satisfy a nicotine craving. The container may comprise a replaceable cartridge, which includes a cartridge housing and a passageway in the housing in which a nicotine reservoir is located. The reservoir holds a measured amount of nicotine in the form of the nicotine carrier. The measured amount of nicotine is an amount suitable for delivering a specific number of “doses”. The form of the nicotine carrier is such as to allow nicotine vapor to be released into a fluid stream passing around or through the reservoir. This process is known as aerosolization and or atomization. Aerosolization is the process or act of converting a physical substance into the form of particles small and light enough to be carried on the air, i.e., into an aerosol. Atomization is the process or act of separating or reducing a physical substance into fine particles and may include the generation of aerosols. The passageway generally has an opening at each end for communication with the exterior of the housing and for allowing the fluid stream through the passageway. A nicotine-impermeable barrier seals the reservoir from atmosphere. The barrier includes passageway barrier portions for sealing the passageway on both sides of the reservoir. These barrier portions are frangible so as to be penetrable for opening the passageway to atmosphere.

A device or a system that is powered can fall into two sub-categories. In both subcategories, such devices or systems may comprise electronic devices or systems that permit a user to simulate the act of smoking by producing an aerosol mist or vapor that is drawn into the lungs through the mouth and then exhaled. The electronic devices or systems typically cause the vaporization of a liquid containing nicotine and entrainment of the vapor into an airstream. Vaporization of an element or compound is a phase transition from the liquid phase to vapor, i.e., evaporation or boiling. In use, the user experiences a similar satisfaction and physical sensation to those experienced from a traditional smoking or tobacco product and exhales an aerosol mist or vapor of similar appearance to the smoke exhaled when using such traditional smoking or tobacco products.

A person of ordinary skill in the art will appreciate that devices or systems of the second, powered category as used herein include, but are not limited to, electronic nicotine delivery systems, electronic cigarettes, e-cigarettes, e-cigs, vaping cigarettes, pipes, cigars, cigarillos, vaporizers, and devices of a similar nature that function to produce an aerosol mist or vapor that is inhaled by a user. Such nicotine delivery devices or systems of the second category incorporate a liquid reservoir element generally including a vaporizer or misting element such as a heating element or other suitable element, and are known, inter alia, as atomizers, cartomizers, or clearomizers. Some electronic cigarettes are disposable; others are reusable, with replaceable and refillable parts.

Aerosol delivery devices or systems in a first sub-category of the second, powered category generally use heat and/or ultrasonic agitation to vaporize a solution comprising nicotine and/or other flavoring, propylene glycol and/or glycerin-based base into an aerosol mist of vapor for inhalation.

Aerosol delivery devices or systems in a second sub-category of the second, powered category may typically comprise devices or systems in which tobacco is heated rather than combusted. During use, volatile compounds may be released from the tobacco by heat transfer from the heat source and entrained in air drawn through the aerosol delivery device or system. Direct contact between a heat source of the aerosol delivery device or system and the tobacco heats the tobacco to form an aerosol. As the aerosol containing the released compounds passes through the device, it cools and condenses to form an aerosol for inhalation by the user. In such devices or systems, heating, as opposed to burning, the tobacco may reduce the odor that can arise through combustion and pyrolytic degradation of tobacco.

Aerosol delivery devices or systems falling into the first sub-category of powered devices or systems may typically comprise a powered unit, comprising a heater element, which is arranged to heat a portion of a carrier that holds an aerosol precursor. The carrier comprises a substrate formed of a “wicking” material, which can absorb aerosol precursor liquid from a reservoir and hold the aerosol precursor liquid. Upon activation of the heater element, aerosol precursor liquid in the portion of the carrier in the vicinity of the heater element is vaporized and released from the carrier into an airstream flowing around the heater and carrier. Released aerosol precursor is entrained into the airstream to be borne by the airstream to an outlet of the device or system, from where it can be inhaled by a user.

The heater element is typically a resistive coil heater, which is wrapped around a portion of the carrier and is usually located in the liquid reservoir of the device or system. Consequently, the surface of the heater may always be in contact with the aerosol precursor liquid, and long-term exposure may result in the degradation of either or both of the liquid and heater. Furthermore, residues may build up upon the surface of the heater element, which may result in undesirable toxicants being inhaled by the user. Furthermore, as the level of liquid in the reservoir diminishes through use, regions of the heater element may become exposed and overheat.

The present disclosure has been devised in light of the above considerations.

SUMMARY OF THE DISCLOSURE

First Mode: A fluid-transfer article in which part of the region which holds the aerosol precursor is in the form of a flexible diaphragm.

At its most general, the first mode of the present disclosure proposes that a fluid-transfer article is provided in which part of the region which holds the aerosol precursor is in the form of a flexible diaphragm. When the fluid-transfer article is in position adjacent a heater of an aerosol-generation apparatus, the flexible diaphragm is then able to move to alter the positional relationship between the diaphragm and the heater. For example, the diaphragm may move between a position in which it is in contact with the heater, and a position in which it is spaced from the heater. In the first of these positions, contact between the flexible diaphragm and the heater may prevent, or at least limit, the leakage of aerosol precursor from the diaphragm. In the second position, aerosol precursor may pass to the heater more freely.

Thus, the first mode of the present disclosure may provide a fluid-transfer article comprising a first region for holding an aerosol precursor and for transferring said aerosol precursor to an activation surface of a second region of said article, said activation surface being disposed at an end of said article configured for thermal interaction with a heater of an aerosol-generation apparatus, wherein said second region is a flexible diaphragm.

Preferably, the flexible diaphragm is formed from a polymeric wicking material. That polymeric wicking material may comprise Polyetherimide (PEI) and/or Polyether ether ketone (PEEK) and/or Polytetrafluoroethylene (PTFE) and/or Polyimide (PI) and/or Polyethersulphone (PES) and/or Ultra-High Molecular Weight Polyethylene (UHMWPE) and/or Polypropylene (PP) and/or Polyethylene Terephthalate (PET). Preferably, the polymeric wicking material is porous. According to a second aspect of the first mode of the present disclosure, the first mode of the present disclosure may provide an aerosol-generation apparatus comprising a heater and a fluid-transfer article comprising a first region for holding an aerosol precursor and for transferring said aerosol precursor to an activation surface of a second region of said article, said activation surface being disposed at an end of said article configured for thermal interaction with a heater of an aerosol-generation apparatus, wherein said second region is a flexible diaphragm.

In such an apparatus, the flexible diaphragm may be arranged to be movable between the first position in which part of the flexible diaphragm is in contact with the heater and the second position in which said part of the flexible diaphragm is spaced from the heater. Preferably, in such an arrangement, the flexible diaphragm is biased towards the first position.

The aerosol-generation apparatus may form part of an aerosol delivery system which has a carrier and include a housing containing the heater and the fluid-transfer apparatus. The housing may have an inlet and outlet, to define an air-flow pathway between the inlet and outlet. That air-flow pathway may pass between the flexible diaphragm and the heater and be obstructed when the flexible diaphragm is in the first position.

The disclosure includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided.

Second Mode: An aerosol-generation apparatus having a heater, at least part of which deforms or moves during use, such as when the heater is active.

At its most general, the second mode of the present disclosure proposes that an aerosol-generation apparatus has a heater, at least part of which (typically at least a part of a heating surface of which) deforms or moves during use, such as when the heater is active. The heater can thus act in conjunction with a fluid-transfer article which holds an aerosol precursor, a heating surface of the heater interacting with an activation surface of the fluid-transfer article.

In one proposal, when the heater is at a first temperature (e.g., room temperature), it may have a first position in which at least a part of the heating surface is adjacent or in contact with the activation surface. The heater then has a second position which is acquired or adopted when the heater is at a second temperature (e.g., at an elevated temperature to heat the aerosol precursor) in which at least a part of the heating surface is spaced from the activation surface. In the second position, there will then be an air-flow pathway between the heating surface and the activation surface, through which air can pass to receive aerosol and/or vapor corresponding to the heated aerosol precursor, which aerosol and/or vapor is then passed to the user. At the first temperature, the air-flow pathway between the heating surface and the activation surface may be obstructed, which prevents or reduces escape of aerosol precursor from the fluid-transfer article when the device is not being used.

In another general sense, the disclosure proposes that an aerosol-generation apparatus is provided, which has a heater mounted on a heat activatable movement element, which heat activatable movement element causes the heater to move towards or away from a fluid-transfer article which holds an aerosol precursor.

Preferably, the heat activatable movement element moves the heater between a position in which at least a part of its heating surface is in contact with an activation surface of the fluid-transfer article and another position in which said at least a part of the heating surface is spaced from that activation surface to define an air-flow pathway between the activation surface and the heater. In the first of these positions, the heater may restrict or prevent escape of aerosol precursor from the fluid-transfer article. In the second position, the heater is able to heat aerosol precursor which has been transferred to it from the fluid-transfer article, to form a vapor and/or a mixture of aerosol and vapor which is mixed with the air flowing between the activation surface and the heater, which can then pass to the user.

Normally, the heat to cause the heat activatable movement element to move the heater will be heat from the heater itself, so that activation of the heater itself triggers the heat activatable movement element to move the heater away from the activation surface.

In another general sense, the second mode of the present disclosure proposes that an aerosol-generation apparatus is provided, which has a moveable heater, movement of the heater being caused by air flow between the heater and an activation surface of a fluid-transfer article which holds an aerosol precursor.

Thus, in such an arrangement, when the user sucks or inhales on the apparatus, they cause a movement of air through the apparatus, a part of that movement being the air flow which causes the heater to move. As the heater moves away from the fluid-transfer article an air-flow pathway is formed between the heater and the activation surface, and aerosol precursor on the heater is heated to release vapor and/or aerosol into the air which is passing to the user. When the user is not using the apparatus, and no air is flowing, at least a part of the heater is in contact with the fluid-transfer article and so prevents or reduces leakage of aerosol precursor from the fluid-transfer article.

According to a first aspect of the second mode of the present disclosure, there is provided an aerosol-generation apparatus comprising a heater and a fluid-transfer article, the fluid-transfer article comprising a first region for holding an aerosol precursor and for transferring said aerosol precursor to an activation surface of a second region of said fluid-transfer article, said activation surface being disposed for thermal interaction with a heating surface of said heater. At least a part of said heater is moveable between a first position and a second position, at least part of said heating surface being adjacent or in contact with said activation surface when said heater is in said first position, and at least part of said heating surface being spaced from said activation surface when said heater is in said second position. An air-flow pathway is defined between said activation surface and said heating surface when said heater is in said second position and said air-flow pathway is at least partially obstructed due to said adjacence or contact between said at least part of heating surface and said activation surface when said heater is in said first position.

At least a part of said heating surface may be deformable in response to a temperature change between a first temperature and a second temperature, said at least a part of the said heating surface being in a first position at the first temperature and a second position at the second temperature. In the first position, at least a part of said heating surface may be adjacent or in contact with said activation surface such that said at least a part of said heating surface obstructs said air-flow pathway from passing between said at least a part of said heating surface and said activation surface and, in the second position, said at least a part of said heating surface is spaced from said activation surface such that said air-flow pathway passes between said heating surface and said activation surface unobstructed by said at least a part of said heating surface.

Normally, the second temperature is higher than the first temperature, so that deformation of the heater surface occurs as the heater temperature rises. In such circumstances, the first temperature may be, e.g., room or ambient temperature, with the second temperature corresponding to an operating temperature of the heater when the user is using the apparatus.

In an embodiment, said heater is mounted on a heat activatable movement element, and said heat activatable movement element is arranged to move said heater between said first position and said second position. At least a part of said heating surface is in contact with said activation surface when said heater is in said first position.

Preferably, the heat activatable movement element is a bi-metallic element. The bi-metallic element is in thermal contact with the heater, such as by being in direct contact or connected via a heat transfer element.

Thus, it is desirable that the bi-metallic element is thermally connected to the heater so as to be heated thereby.

It is preferable that the heat activatable movement element is arranged to move the heater from the first position to the second position as the temperature of the heat activatable movement member rises.

In another embodiment, said heater may be arranged such that air flow between said heating surface and said activation surface causes said heater to move to said second position from said first position. Optionally, said heater is biased towards said first position. This enables it to remain in contact with the activation surface when no air is flowing in the air-flow pathway, or if the apparatus is moved. The biasing may be resilient biasing means, such as a spring or resilient block.

Optionally, the heater may be mounted on a hinged element so that pivoting of the hinged element enables the movement of the heater between the first and second positions.

Preferably, either or both of the first and second regions are formed from a polymeric wicking material. That polymeric wicking material may comprise Polyetherimide (PEI) and/or Polyether ether ketone (PEEK) and/or Polytetrafluoroethylene (PTFE) and/or Polyimide (PI) and/or Polyethersulphone (PES) and/or Ultra-High Molecular Weight Polyethylene (UHMWPE) and/or Polypropylene (PP) and/or Polyethylene Terephthalate (PET).

The polymeric wicking material may be porous. When both the first and second regions are formed from a porous polymeric wicking material, the pore diameter in the first region of the fluid-transfer article may be greater than the pore diameter in the second region of the fluid-transfer article. This assists transfer of aerosol precursor from the first region to the second region.

According to a second aspect of the second mode of the present disclosure, there is provided an aerosol-generation apparatus comprising a heater and a fluid-transfer article, the fluid-transfer article comprising a first region for holding an aerosol precursor and for transferring said aerosol precursor to an activation surface of a second region of said fluid-transfer article, said activation surface being disposed for thermal interaction with a heating surface of said heater, and an air-flow pathway is defined between an inlet and an outlet of said aerosol-generation apparatus, wherein at least a part of said heating surface is deformable in response to a temperature change between a first temperature and a second temperature, said at least a part of the said heating surface being in a first position at the first temperature and a second position at the second temperature, and wherein, in the first position, at least a part of said heating surface is adjacent or in contact with said activation surface such that said at least a part of said heating surface obstructs said air-flow pathway from passing between said at least a part of said heating surface and said activation surface and, in the second position, said at least a part of said heating surface is spaced from said activation surface such that said air-flow pathway passes between said heating surface and said activation surface unobstructed by said at least a part of said heating surface. According to a third aspect of the second mode of the present disclosure, there is provided an aerosol-generation apparatus comprising a heater and a fluid-transfer article, the fluid-transfer article comprising a first region for holding an aerosol precursor and for transferring said aerosol precursor to an activation surface of a second region of said article, said activation surface being disposed for thermal interaction with a heating surface of said heater, said heater being mounted on a heat activatable movement element, said heat activatable movement element being arranged to move said heater between a first position and a second position, at least a part of said heating surface being in contact with said activation surface when said heater is in said first position, and said at least a part of said heating surface being spaced from said activation surface when said heater is in said second position, whereby an air-flow pathway is defined between said activation surface and said heating surface when said heater is in said second position and said air-flow pathway is at least partially obstructed due to said contact between at least a part of said heating surface and said activation surface when said heater is in said first position.

According to a fourth aspect of the second mode of the present disclosure, there is provided an aerosol-generation apparatus comprising a heater and a fluid-transfer article, the fluid-transfer article comprising a first region for holding an aerosol precursor and for transferring said aerosol precursor to an activation surface of a second region of said article, said activation surface being disposed for thermal interaction with a heating surface of said heater, said heater being moveable between a first position and a second position, at least part of said heating surface being in contact with said activation surface when said heater is in said first position, at least part of said heating surface being spaced from said activation surface when said heater is in said second position, whereby an air-flow pathway is defined between said activation surface and said heating surface when said heater is in said second position and said air-flow pathway is at least partially obstructed due to said contact between said at least part of heating surface and said activation surface when said heater is in said first position, said heater being arranged such that air flow between said heating surface and said activation surface causes said heater to move to said second position from said first position.

In a fifth aspect, the second mode of the present disclosure may also provide an aerosol delivery system including an aerosol-generation apparatus in accordance with the first, second, third or fourth aspects discussed above, and a carrier. The carrier may then have a housing containing the heater and the fluid-transfer article. This housing may have an inlet and an outlet, the former being in communication with the inlet of the aerosol-generation apparatus and the latter being in communication with the outlet of the aerosol-generation apparatus. The air-flow pathway then may extend between the inlet and the outlet of the housing, so that movable air can be drawn into the housing from the exterior, through the inlet, and out from the outlet to the user. When the apparatus is being used, the aerosol and/or vapor will be present in the air that passes to the user from the outlet. The aerosol-generation apparatus may form part of an aerosol delivery system which has a carrier and include a housing containing the heater and the fluid-transfer apparatus. The housing may have an inlet and outlet, and the air-flow pathway extends to the inlet and outlet of the housing.

The disclosure includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided.

Third Mode: A fluid-transfer article for holding an aerosol precursor including a hole and a heater adjacent to the hole which is deformable in response to temperature change.

At its most general, the third mode of the present disclosure proposes that a fluid-transfer article for holding an aerosol precursor includes a hole therein. Adjacent the hole is a heater, which is deformable in response to temperature change, the deformation being between a position in which a part of the heater (typically, part of the heating surface of the heater) blocks the hole, and a position in which the heater is spaced from the fluid-transfer article. With such an arrangement, the heater may prevent or reduce escape of aerosol precursor from the fluid-transfer article when it is not being used but allow aerosol precursor to reach the heater and be vaporized when the aerosol-generation apparatus is in use.

There may be more than one hole in the fluid-transfer article, in which case the deformation of the heater will normally need to block all, or at least most of the holes when in the first position. Hence, the third mode of the present disclosure may provide an aerosol-generation apparatus comprising a heater and a fluid-transfer article, the fluid-transfer article comprising a first region for holding an aerosol precursor and for transferring said aerosol precursor to a second region of said article, said second region having at least one hole therein for passage of said aerosol precursor therethrough, wherein at least a part of a heating surface of said heater is deformable in response to a temperature change between a first temperature and a second temperature said at least a part of said heating surface of said heater being in a first position at the first temperature and a second position at the second temperature, and wherein: in the first position said at least a part of the heating surface is in contact with said second region so as to obstruct said at least one hole, and in the second position said at least part of the heating surface is spaced from said second region.

Preferably, an air-flow pathway is defined between an inlet and an outlet of said aerosol-generation apparatus, and wherein: when said at least a part of said heating surface is in contact with said second region, a part of said air-flow pathway between said at least a part of said heating surface and said second region is obstructed by said heater: and when said at least a part of said heating surface is spaced from said second region, said air-flow pathway between said at least a part of said heating surface and said second region is not obstructed by said heater.

Optionally, said second region may include a plate having said hole therein and wherein: in said first position said at least a part of the heating surface is in contact with said plate so as to obstruct said at least one hole, and in the second position said at least part of the heating surface is spaced from said second plate.

In some embodiments, said plate may be formed from metal. In other embodiments, said plate may be formed of plastic material.

In addition to the plate, the second region may include a part formed of polymer wicking material. In such a case, the part of polymeric wicking material will be between the first region and the plate, it can then transfer aerosol precursor from the first part to the hole in the plate.

Preferably, the first region and said part of the second region (if present) is formed from a polymeric wicking material.

The polymeric wicking material is preferably porous. It may be configured so that the pore diameter in the first region of the fluid-transfer article is greater than the pore diameter in the second region of the fluid-transfer article.

Normally, the second temperature is higher than the first temperature, so the deformation of the heater surface to the second position occurs as the heater temperature rises. In such circumstances, the first temperature may be, e.g., room or ambient temperature, with the second temperature corresponding to operating temperature of the heater when the user is using the apparatus.

In a second aspect of the disclosure, the third mode of the present disclosure may also provide an aerosol delivery system including an aerosol-generation apparatus discussed above, and a carrier. The carrier may then be in a housing containing the heater and the fluid-transfer article. This housing may have an inlet and an outlet, the former being in communication with the inlet of the aerosol-generation apparatus and the latter being in communication with the outlet of the aerosol-generation apparatus. The air-flow pathway then may extend between the inlet and the outlet of the housing, so that movable air can be drawn into the housing from the exterior, through the inlet, and out from the outlet to the user. When the apparatus is being used, aerosol and/or vapor due to the action of the heater on the aerosol precursor will be present in the air that passes to the user from the outlet.

The aerosol-generation apparatus may form part of an aerosol delivery system which has a carrier which includes a housing containing the heater and the fluid-transfer apparatus. The housing may have an inlet and outlet, to define an air-flow pathway between the inlet and outlet.

Preferably, that air-flow pathway may pass between the second region (and optionally the plate thereof, if provided) and said at least a part of the heating surface of the heater and be obstructed when said as least part of said heating surface is in the first position.

The disclosure includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided.

Fourth Mode: A fluid-transfer article having one or more heat activatable valves which control transfer of aerosol precursor to an activation surface of the article.

At its most general, the fourth mode of the present disclosure proposes that a fluid-transfer article has a heat activatable valve, or possibly a plurality of such valves, which controls transfer of aerosol precursor to an activation surface of the article. In use of the fluid-transfer article, the activation surface will normally be disposed at an end of the article configured for thermal interaction with a heating surface of a heater of an aerosol-generation apparatus.

In such an arrangement, the valve may reduce or eliminate escape of aerosol precursor from the article when the article is not being used, and the heater is not activated, but permit aerosol precursor to reach the activation surface to be heated when the article is in use.

Thus, according to a first aspect of the fourth mode of the present disclosure, there may be provided a fluid-transfer article comprising a first region for holding an aerosol precursor and for transferring said aerosol precursor to an activation surface of a second region of said article, said activation surface being disposed at an end of said article configured for thermal interaction with a heating surface of a heater of an aerosol-generation apparatus; the article further including at least one heat activatable valve for controlling the transfer of said aerosol precursor from said first region to said activation surface.

Optionally, the or each heat activatable valve is between the first region and the second region. In such an arrangement, the valve or valves control the transfer of the aerosol precursor from the first region to the second region. The second region may then be arranged to transfer aerosol precursor from the or each valve to the activation surface. To do this, the second region may be formed from a wicking material, preferably a polymeric wicking material. In a possible arrangement of the fourth mode of the present disclosure said second region may comprise at least one discontinuity in said activation surface to form a corresponding at least one channel between said activation surface and said heating surface, the or each said channel being configured for providing an air-flow pathway across said activation surface as such at least one channel is provided, the activation surface may preferably include at least one angled surface portion and being configured said that, when said fluid-transfer article is arranged with respect to said heating surface for thermal interaction therebetween the or each angled surface portion forms an acute intersection angle with said heating surface, the or each said channel being at least partially defined by a said angled surface portion in the form of a wall of said channel. It is then possible that the or each said channel is a least partially defined by a pair of said angled surface portions, said pair of angled surface portions opposing one another across said channel to form opposite walls of said channel.

Alternatively, where the second region comprises at least one discontinuity in the activation surface to form a corresponding at least one channel, the activation surface may include at least one arcuate surface portion and being configured such that, when the fluid-transfer article is arranged with respect to said heating surface for thermal interaction therebetween, the or each arcuate surface portion opposes said heating surface and is concave towards said heating surface, said arcuate surface portion defining at least part of an internal surface of said channel.

In another option within the fourth mode of the present disclosure, the heat activatable valve or valves may form the second region of the fluid-transfer article and a surface of the valve or valves may then be the activation surface. In this case, the valve or valves are then the closest part of the fluid-transfer article to the heating surface of the aerosol-generation apparatus.

In this case, the valve or valves may be separable from the first region of the fluid-transfer article. This allows the first region, which contains aerosol precursor, to be replaced without needing to replace the valve.

In any of the above arrangements, the first region may be formed from wicking material, preferably a polymeric wicking material, and that wicking material may be porous.

In any of the above arrangements, it is preferable that the heat to activate the valve is generated by the heater.

In a second aspect of the fourth mode of the present disclosure, there may be provided an aerosol-generation apparatus comprising a heater which includes a heating surface and a fluid-transfer article as discussed above. When the activation surface is formed from a surface of the valve or valves, or when the activation surface is a surface of the second region of the fluid-transfer article, with the valve or valves between the first and second regions such that activation surface is spaced from the heating surface of the heater, to form an air-flow pathway between the activation surface and the heating surface. The heater may include a heat conduction element forming the heating surface of the heater facing the activation surface.

The fourth mode of the present disclosure may further provide an aerosol delivery system comprising an aerosol-generation apparatus as discussed above and a carrier. The carrier may comprise a housing containing the heater and the fluid-transfer article, the housing having an inlet and an outlet in communication with the air-flow pathway.

The disclosure includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided.

Fifth Mode: An aerosol-generation apparatus having a heater which has a heating region in abutting unbonded contact with a wick of a fluid-transfer article.

At its most general, the fifth mode of the present disclosure proposes that an aerosol-generation apparatus has a heater which has a heating region in abutting unbonded contact with a wick of a fluid-transfer article. The fluid-transfer article is separable (e.g., removable) from the heater, and includes a reservoir for holding an aerosol precursor and a wick. The wick transfers the aerosol precursor from the reservoir towards the heating region of the heater. The heating region is flexible, so that it may deform due to the contact between the heating region and the wick. This allows it to conform to the shape of the wick.

Thus, when the fluid-transfer article is in place in the aerosol-generation apparatus, aerosol precursor may pass through the wick to the heating region of the heater, to be heated thereby when the heater is active. This forms a vapor or vapor/aerosol mixture, which may then pass to the user in an air flow. The flexibility of the heating region means that, when the fluid-transfer article is inserted into the rest of the aerosol-generation apparatus, the heating region will conform to the wick which it contacts. The separability of the fluid-transfer article means that the fluid-transfer article can be removed (e.g., when the aerosol precursor has been used up) and replaced.

Thus, according to the fifth mode of the present disclosure, there may be provided an aerosol-generation apparatus comprising a heater and a fluid-transfer article, the fluid-transfer article comprising a reservoir for holding an aerosol precursor and a wick arranged and configured to receive said aerosol precursor from said reservoir, the wick making abutting unbonded contact with a heating region of said heater, wherein said heating region of said heater is flexible, thereby to be deformable due to said contact between said wick and said heating region, and wherein said fluid-transfer article and said heater are separable.

Preferably, the heating region is resilient. This may enable the abutting unbonded contact between the heating region and the wick to be a resilient contact.

The wick may be U-shaped with the base of the U-shape making the unbonded contact with the heating region.

Preferably, there will be a sealing member sealing the reservoir, to prevent leakage of aerosol precursor. The wick may then extend through the sealing member into the reservoir. This enables it to receive aerosol precursor from the reservoir and to pass that aerosol precursor to the heating surface. Where such a sealing member is used, and the flexible wick is U-shaped, both arms of the U-shape may extend through the sealing member.

The wick may be relatively rigid. For example, it may be made of a porous polymeric material. Optionally, however, the wick itself is flexible, and may then be made of a cord material, although other materials are possible. When the wick is flexible, it is desirable that it is less flexible than the heating surface, so that it is the heating surface which flexes to conform to the wick.

There will normally be an air-flow pathway past the heating region, to enable air to pass to the user. When the heater is active, the air flowing along the air-flow pathway will receive vapor and/or vapor/aerosol mixture from the heated wick, which vapor or mixture can pass to the user with the air flow.

As mentioned above the fluid-transfer article is normally separable from the rest of the aerosol-generation apparatus. There may therefore be provided a carrier with a first housing containing the reservoir and supporting the wick. A second housing supporting the heater may also be provided, with those housings then separable. In such an arrangement, the housing containing the reservoir may have an outlet, and the housing supporting the heater have an inlet, so that the air-flow pathway extends to the inlet and outlet to enable air to flow to the user.

The disclosure includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided.

Sixth Mode: An aerosol-generation apparatus having a heater which has a heating region in contact with a wick of a fluid-transfer article.

At its most general, the sixth mode of the present disclosure proposes that an aerosol-generation apparatus has a heater which has a heating region in contact with a wick of a fluid-transfer article. The fluid-transfer article includes a reservoir for holding an aerosol precursor, and a wick. The wick transfers aerosol precursor from the reservoir towards the heating region of the heater. The heating region includes at least one electrically conductive filament, which generates heat when electrical current is passed therethrough. The at least one filament has a coating of electrical insulating material thereon, the coating having a thickness not greater than 50 μm. Thus, the element which generates the heat to heat the wick has a layer of electrically insulating material thereon. The electrical insulation helps to reduce the risk of a short circuit if the heating element (or even the whole heater) is deformed. It may also reduce the risk of aerosol precursor burning onto the surface of the filament when aerosol precursor passes through the wick to the heating region. This may prolong the performance of the heater.

The electrical insulation may have the side effect of delaying or reducing heat transfer to the wick, and for this reason it is preferable that the electrical insulating material has good thermal conductance.

Thus, according to the sixth mode of the present disclosure, there may be provided an aerosol-generation apparatus comprising a heater and a fluid-transfer article, the fluid-transfer article comprising a reservoir for holding an aerosol precursor and a wick arranged and configured to receive said aerosol precursor from said reservoir, the wick making contact with a heating region of said heater, wherein said heating region of said includes at least one electrically conductive filament arranged to generate heat on the passage of electrical current therethrough, said at least one filament having a coating of electrically insulating material thereon, said coating having a thickness not greater than 50 μm.

Preferably, the coating has a resistance greater than 20Ω within two points thereof. More preferably, distance is greater than 1MΩ between any two points.

Suitable materials for the coating include silicone, which may be sprayed on the filament or filaments, or potassium silicate paint, which may be applied to the filament or filaments. Preferably, the contact between the wick and the heating region is unbonded so that the wick abuts against the heater without being attached thereto. This enables the apparatus to be designed so that the fluid-transfer article and the heater are separable. Separability allows the fluid-transfer article to be removable, which will allow it to be refilled or replaced when the aerosol precursor which it contains has been consumed.

Preferably, the heating region of the heater is flexible, so that it deforms due to contact between the wick and the heating region. The flexibility of the heating region means that it will conform to the shape of the wick which it contacts. This ensures good thermal transfer between the heating region and the wick. Hence, aerosol precursor will pass through the wick to the heating region of the heater to be heated thereby when the heater is active, so good thermal contact ensures efficient formation of vapor or vapor/aerosol mixture, which may then pass to the user in an air flow.

Preferably, the heating region is resilient. This may enable an abutting unbonded contact between the heating region and the wick to be a resilient contact.

The wick may be U-shaped with the base of the U-shape making the unbonded contact with the heating surface.

Preferably, there will be a sealing member sealing the reservoir, to prevent leakage of aerosol precursor. The wick may then extend through the sealing member into the reservoir. This enables it to receive aerosol precursor from the reservoir and to pass that aerosol precursor to the heating surface. Where such a sealing member is used, and the wick is U-shaped, both arms of the U-shape may extend through the sealing member. The wick may be relatively rigid. For example, it may be made of a porous polymeric material. Optionally, however, the wick itself is flexible, and may then be made of a cord material, although other materials are possible. When the wick is flexible, it is desirable that it is less flexible than the heating surface, so that it is primarily the heating surface which flexes to conform to the wick. The heating region of the heater, and in particular, the filament thereof, may have a convoluted shape. Alternatively, the heating region may comprise an insulating substrate, with a filament thereon, which filament may follow a convoluted path on the substrate. Such convoluted shapes allow good contact between the filament of the heating region and the wick, without requiring precise relative positioning.

There will normally be an air-flow pathway past the heating region, to enable air to pass to the user. When the heater is active, the air flowing along the air-flow pathway will receive vapor and/or vapor/aerosol mixture from the heated wick, which vapor or mixture can pass to the user with the air flow.

As mentioned above the fluid-transfer article is normally separable from the rest of the aerosol-generation apparatus. There may therefore be provided a carrier with a first housing containing the reservoir and supporting the wick. A second housing supporting the heater may also be provided, with those housings then being separable. In such an arrangement, the housing containing the reservoir may have an outlet, and the housing supporting the heater have an inlet, so that the air-flow pathway extends between the inlet and outlet to enable air to flow to the user.

The disclosure includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided.

Seventh Mode: An aerosol-generation apparatus having a wick which receives aerosol precursor from a reservoir, and which has an activation surface which makes abutting and unbonded contact with a heater.

At its most general, an aspect of the seventh mode of the present disclosure proposes that an aerosol-generation apparatus has a wick which receives aerosol precursor from a reservoir, and which has an activation surface which makes abutting and unbonded contact with a heater. The wick is supported by a resilient wick support element which biases the wick towards the heater, so that the abutting unbonded contact is a resilient contact. In this way, the wick may be kept in good contact with the heater when the apparatus is being used, but the reservoir and wick may be made separable from the heater and other parts of the apparatus to allow the replacement of the aerosol precursor once it has been consumed as a consequence of use of the apparatus. The wick, wick support element and reservoir may form parts of a fluid-transfer article, and the aerosol precursor may be replaced by replacement of one fluid-transfer article with another. Thus, the fluid-transfer article may form part of the consumable or cartomizer, which can be replaced when the aerosol precursor in the reservoir has been consumed. The heater, on the other hand, may be part of the main body, so that it can be reused by connecting it to a new consumable.

The aerosol-generation apparatus may form part of an aerosol delivery device, having a first casing containing the reservoir and supporting the wick and the wick support element and a second casing supporting the heater. The second casing may also contain a power source, such as a battery, for the heater. The first casing may have an outlet, and the second casing an inlet, to allow air to flow into the device from the inlet to the activation surface, and from the activation surface to the outlet. Thus, when a user sucks or “draws” on the outlet, air will pass through the device and aerosol precursor will be released from the activation surface as vapor or a mixture of vapor and aerosol when the wick is heated by the heater, so that the vapor or mixture can pass to the outlet and then to the user.

Thus, the seventh mode of the present disclosure may provide an aerosol-generation apparatus comprising a heater and a fluid-transfer article, the fluid-transfer article comprising a reservoir for holding an aerosol precursor, a wick arranged to receive aerosol precursor from said reservoir, and a wick support element; wherein said wick support element is arranged to support said wick such that said heater makes abutting unbonded contact with an activation surface of said wick so as to interact thermally with said activation surface; and wherein said wick support element is resilient, and is arranged to bias said wick towards said heater, whereby said abutting unbonded contact is resilient contact.

Preferably, the activation surface of the wick is planar.

Normally, the wick support element will be between the wick and the reservoir. It may then form an end wall of the reservoir.

Aerosol precursor needs to be able to pass from the reservoir to the wick, and to achieve this it is preferable that the wick support element has at least one bore therethrough for passage of the aerosol precursor from the reservoir to the wick. Each bore may be sized to define at least one corresponding non-capillary duct through the wick support element. In this way the aerosol precursor is able to flow in a non-capillary manner from the reservoir to the wick through said at least one bore.

Another possibility is for the or each bore to be a capillary duct (also referred to herein as a capillary bore), so that the flow of aerosol precursor therethrough is controlled by capillary action. In such a case, the or each bore forming a capillary duct may have a diameter of at least 0.3 mm, more preferably at least 0.5 mm, but preferably not greater than 2 mm. For example, the or each capillary duct may have a diameter of 0.8 to 1.5 mm. If the or each bore is a capillary duct, the flow of aerosol precursor therethrough will be influenced by the length of the or each bore, which length is determined by the thickness of the wick support element. It is preferable in such circumstances that the wick support element has a thickness of at least 0.5 mm, more preferably 1 mm between the reservoir and the wick. It is also preferable that the wick support element has a thickness not greater than 5 mm between the reservoir and the wick. Greater thicknesses may limit the amount of aerosol precursor which reaches the wick. The wick support element may be formed of rubber material, and the wick may be formed of silica material.

In a second aspect of the seventh mode of the present disclosure, there may be provided an aerosol delivery device comprising an aerosol-generation apparatus as discussed above, together with a first casing containing the reservoir and supporting the wick and the wick support element, and a second casing supporting the heater. The first and second casings are then preferably separably interconnected. In this way, the first casing and the elements it contains and supports may form a consumable of the smoking substitute device. The second casing and the elements it contains and supports may then form the main body of the aerosol generation device. In such an arrangement, the first casing will normally have an outlet, with a first air-flow pathway from the activation surface of the wick to the outlet. Similarly, the second casing may have an inlet, with a second air-flow pathway from the inlet to the activation surface.

It is convenient if the wick and the wick support element have aligned openings therethrough, which aligned openings form part of the first air-flow pathway from the activation surface to the outlet. This allows a convenient route for air and vapor or a mixture of aerosol and vapor to pass from the activation surface to the outlet of the first casing to reach the user.

At its most general, another aspect of the seventh mode of the present disclosure proposes that an aerosol-generation apparatus has a heater which has a heating surface in abutting unbonded contact with a flexible wick of a fluid-transfer article. The fluid-transfer article is separable (e.g., removable) from the rest of the aerosol-generation apparatus and includes a reservoir for holding an aerosol precursor from which reservoir the wick extends.

Thus, when the fluid-transfer article is in place in the aerosol-generation apparatus, aerosol precursor may pass through the wick to the heating surface of the heater, to be heated thereby when the heater is active. This forms a vapor or vapor/aerosol mixture, which may then pass to the user in an air flow. The flexibility of the wick means that, when the fluid-transfer article is inserted into the rest of the aerosol-generation apparatus, it can conform to the heating surface which it contacts. The separability of the fluid-transfer article means that the fluid-transfer article can be removed (e.g., when the aerosol precursor has been used up) and replaced. Thus, according to the seventh mode of the present disclosure, there may be provided an aerosol-generation apparatus comprising a heater and a fluid-transfer article, the fluid-transfer article being separable from the rest of the aerosol-generation apparatus and comprising a reservoir for holding an aerosol precursor and a flexible wick extending from said reservoir, the flexible wick extending to a heating surface of said heater and making abutting unbonded contact therewith. Preferably, the flexible wick is resilient. This may enable the abutting unbonded contact between the heating surface and the flexible wick to be a resilient contact.

The flexible wick may be U-shaped with the base of the U-shape making the unbonded contact with the heating surface.

Normally, there will be a sealing member sealing the reservoir, to prevent leakage of aerosol precursor. The flexible wick may then extend through the sealing member into the reservoir. This enables it to receive aerosol precursor from the reservoir and to pass that aerosol precursor to the heating surface. Where such a sealing member is used, and the flexible wick is U-shaped, both arms of the U-shape may extend through the sealing member.

The flexible wick is normally made of a cord material, although other materials are possible. There will normally be an air-flow pathway along the heating surface, to enable air to pass to the user. When the heater is active, the air flowing along the air-flow pathway will receive vapor and/or vapor/aerosol mixture from the heated wick, which vapor or mixture can pass to the user with the air flow.

As mentioned above the fluid-transfer article is normally separable from the rest of the aerosol-generation apparatus. There may therefore be provided a carrier with a first housing containing the reservoir and supporting the flexible wick. A second housing containing the heater may also be provided, with those housings then separable. In such an arrangement, the housing containing the reservoir may have an outlet, and the housing containing the heater have an inlet, so that the air-flow pathway extends to the inlet and outlet to enable air to flow to the user.

The disclosure includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided.

BRIEF DESCRIPTION OF THE FIGURES

So that the disclosure may be understood, and so that further aspects and features thereof may be appreciated, embodiments illustrating the principles of the disclosure will now be discussed in further detail with reference to the accompanying figures, in which:

FIG. 1 is a perspective view illustration of a system for aerosol delivery according to one or more embodiments of the first mode of the present disclosure;

FIG. 2 is a cross-section side view illustration of part of an apparatus of the system for aerosol delivery of FIG. 1;

FIG. 3 is a cross-section side view illustration of the system and apparatus for aerosol delivery of FIG. 1;

FIG. 4 is a perspective view illustration of an aerosol carrier for use in the system for aerosol delivery according to one or more embodiments of the first mode of the present disclosure;

FIG. 5 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to one or more embodiments of the first mode of the present disclosure;

FIG. 6 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to one or more embodiments of the first mode of the present disclosure, in an alternative configuration from that of FIG. 5;

FIG. 7 is a cross-section side view of aerosol carrier according to one or more embodiments of the first mode of the present disclosure;

FIG. 8 is a perspective cross-section side view of the aerosol carrier of FIG. 7;

FIG. 9 is an exploded perspective view illustration of a kit-of-parts for assembling the system according to one or more embodiments of the first mode of the present disclosure;

FIG. 10 is a perspective view illustration of a system for aerosol delivery according to one or more embodiments of the second mode of the present disclosure;

FIG. 11 is a cross-section side view illustration of part of an apparatus of the system for aerosol delivery of FIG. 10;

FIG. 12 is a cross-section side view illustration of the system and apparatus for aerosol delivery of FIG. 10;

FIG. 13 is a perspective view illustration of an aerosol carrier for use in the system for aerosol delivery according to one or more embodiments of the second mode of the present disclosure;

FIG. 14 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to one or more embodiments of the pre second mode of the present disclosure;

FIG. 15 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to one or more embodiments of the second mode of the present disclosure, FIG. 15 being perpendicular to FIG. 14 and showing the heater in a heated state;

FIG. 16 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to one or more embodiments of the second mode of the present disclosure, FIG. 16 corresponding to FIG. 14, but showing the heater in a heated state;

FIG. 17 is a cross-section side view of an aerosol carrier according to one or more embodiments of the second mode of the present disclosure;

FIG. 18 is a perspective cross-section side view of the aerosol carrier of FIG. 18;

FIG. 19 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to one or more alternative embodiments of the second mode of the present disclosure;

FIG. 20 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to one or more alternative embodiments of the second mode of the present disclosure;

FIG. 21 is a cross-section side view of elements of another aerosol carrier and a part of an apparatus of the system for aerosol delivery according to another alternative embodiment of the second mode of the present disclosure in one configuration;

FIG. 22 is a cross-section side view of elements of the aerosol carrier and a part of an apparatus of the system for aerosol delivery corresponding to FIG. 21, but in an alternative configuration;

FIG. 23 is a cross-section side view of elements of yet another aerosol carrier and a part of an apparatus of the system for aerosol delivery according to another embodiment of the second mode of the present disclosure in one configuration;

FIG. 24 is a cross-section side view of elements of the aerosol carrier and a part of an apparatus of the system for aerosol delivery corresponding to FIG. 23, but in alternative configuration;

FIG. 25 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to yet another embodiment of the second mode of the present disclosure;

FIG. 26 is a cross-section view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery corresponding to FIG. 25, but in an alternative configuration;

FIG. 27 is a cross-section side view of aerosol carrier according to one or more embodiments of the second mode of the present disclosure;

FIG. 28 is a perspective cross-section side view of the aerosol carrier of FIG. 27;

FIG. 29 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to one or more further embodiments of the second mode of the present disclosure;

FIG. 30 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to one or more further embodiments of the second mode of the present disclosure;

FIG. 31 is a cross-section side view of elements of another aerosol carrier and a part of an apparatus of the system for aerosol delivery according to another further embodiment of the second mode of the present disclosure in one configuration;

FIG. 32 is a cross-section side view of elements of the aerosol carrier and a part of an apparatus of the system for aerosol delivery corresponding to FIG. 31, but in an alternative configuration;

FIG. 33 is a cross-section side view of elements of yet another aerosol carrier and a part of an apparatus of the system for aerosol delivery according to another embodiment of the second mode of the present disclosure;

FIG. 34 is a cross-section side view of elements of the aerosol carrier and a part of an apparatus of the system for aerosol delivery corresponding to FIG. 33, but in alternative configuration;

FIG. 35 is a cross-section side view of aerosol carrier according to one or more embodiments of the second mode of the present disclosure;

FIG. 36 is a perspective cross-section side view of the aerosol carrier of FIG. 35;

FIG. 37 is an exploded perspective view illustration of a kit-of-parts for assembling the system according to one or more embodiments of the second mode of the present disclosure;

FIG. 38 is a perspective view illustration of a system for aerosol delivery according to one or more embodiments of the third mode of the third mode of the present disclosure;

FIG. 39 is a cross-section side view illustration of part of an apparatus of the system for aerosol delivery of FIG. 38;

FIG. 40 is a cross-section side view illustration of the system and apparatus for aerosol delivery of FIG. 38;

FIG. 41 is a perspective view illustration of an aerosol carrier for use in the system for aerosol delivery according to one or more embodiments of the third mode of the present disclosure;

FIG. 42 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to one or more embodiments of the third mode of the present disclosure;

FIG. 43 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to one or more embodiments of the third mode of the present disclosure, perpendicular to FIG. 42, and with the heater in a heated condition;

FIG. 44 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to one or more embodiments of the third mode of the present disclosure, FIG. 44 corresponding to FIG. 42 but with the heater in a heated condition;

FIG. 45 is a cross-section side view of an aerosol carrier according to one or more embodiments of the third mode of the present disclosure;

FIG. 46 is a perspective cross-section side view of the aerosol carrier of FIG. 45;

FIG. 47 is an exploded perspective view illustration of a kit-of-parts for assembling the system according to one or more embodiments of the third mode of the present disclosure;

FIG. 48 is a perspective view illustration of a system for aerosol delivery according to one or more embodiments of the fourth mode of the present disclosure;

FIG. 49 is a cross-section side view illustration of part of an apparatus of the system for aerosol delivery of FIG. 48;

FIG. 50 is a cross-section side view illustration of the system and apparatus for aerosol delivery of FIG. 48;

FIG. 51 is a perspective view illustration of an aerosol carrier for use in the system for aerosol delivery according to one or more embodiments of the fourth mode of the present disclosure;

FIG. 52 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to one or more embodiments of the fourth mode of the present disclosure;

FIG. 53 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to one or more embodiments of the fourth mode of the present disclosure;

FIG. 54 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to one or more embodiments of the fourth mode of the present disclosure;

FIG. 55 is a cross-section side view of aerosol carrier according to one or more embodiments of the fourth mode of the present disclosure;

FIG. 56 is a perspective cross-section side view of the aerosol carrier of FIG. 54;

FIG. 57 is an exploded perspective view illustration of a kit-of-parts for assembling the system according to one or more embodiments of the fourth mode of the present disclosure;

FIG. 58 is a perspective view illustration of a system for aerosol delivery according to one or more embodiments of the fifth mode of the present disclosure;

FIG. 59 is a cross-section side view illustration of part of an apparatus of the system for aerosol delivery of FIG. 58;

FIG. 60 is a cross-section side view illustration of the system and apparatus for aerosol delivery of FIG. 58;

FIG. 61 is a perspective view illustration of an aerosol carrier for use in the system for aerosol delivery according to one or more embodiments of the fifth mode of the present disclosure;

FIG. 62 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to one or more embodiments of the fifth mode of the present disclosure;

FIG. 63 shows in more detail the configuration of the heater in the arrangement of FIG. 62;

FIG. 64 is a cross-section side view of aerosol carrier according to one or more embodiments of the fifth mode of the present disclosure;

FIG. 65 is a perspective cross-section side view of the aerosol carrier of FIG. 64;

FIG. 66 is an exploded perspective view illustration of a kit-of-parts for assembling the system according to one or more embodiments of the fifth mode of the present disclosure;

FIG. 67 is a perspective view illustration of a system for aerosol delivery according to one or more embodiments of the sixth mode of the present disclosure;

FIG. 68 is a cross-section side view illustration of part of an apparatus of the system for aerosol delivery of FIG. 67;

FIG. 69 is a cross-section side view illustration of the system and apparatus for aerosol delivery of FIG. 67;

FIG. 70 is a perspective view illustration of an aerosol carrier for use in the system for aerosol delivery according to one or more embodiments of the sixth mode of the present disclosure;

FIG. 71 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to one or more embodiments of the sixth mode of the present disclosure;

FIG. 72 shows in more detail one possible configuration of the heater in the arrangement of FIG. 71;

FIG. 73 shows in more detail a second possible configuration of the heater in the arrangement of FIG. 71;

FIG. 74 is a cross-section side view of aerosol carrier according to one or more embodiments of the sixth mode of the present disclosure;

FIG. 75 is a perspective cross-section side view of the aerosol carrier of FIG. 74;

FIG. 76 is an exploded perspective view illustration of a kit-of-parts for assembling the system according to one or more embodiments of the sixth mode of the present disclosure;

FIG. 77 is a perspective view illustration of a system for aerosol delivery according to one or more embodiments of the seventh mode of the present disclosure;

FIG. 78 is a cross-section side view illustration of part of an apparatus of the system for aerosol delivery of FIG. 77;

FIG. 79 is a cross-section side view illustration of the system and apparatus for aerosol delivery of FIG. 77;

FIG. 80 is a perspective view illustration of an aerosol carrier for use in the system for aerosol delivery according to one or more embodiments of the seventh mode of the present disclosure;

FIG. 81 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to one or more embodiments of the seventh mode of the present disclosure;

FIG. 82 is a cross-section side view of elements of an aerosol carrier and a part of an apparatus of the system for aerosol delivery according to one or more embodiments of the seventh mode of the present disclosure, in an alternative configuration from that of FIG. 81;

FIG. 83 is a cross-section side view of aerosol carrier according to one or more embodiments of the seventh mode of the present disclosure;

FIG. 84 is a perspective cross-section side view of the aerosol carrier of FIG. 83;

FIG. 85 is an exploded perspective view illustration of a kit-of-parts for assembling the system according to one or more embodiments of the seventh mode of the present disclosure;

FIG. 86 shows a schematic drawing of a first arrangement of a smoking substitute system;

FIG. 87 shows another schematic drawing of the first arrangement of the smoking substitute system;

FIG. 88 shows a schematic drawing of a second arrangement of a smoking substitute system;

FIG. 89 shows another schematic drawing of the second arrangement of the smoking substitute system;

FIG. 90 shows a cutaway view of part of a third arrangement of a smoking substitute system;

FIG. 91 shows a cross-sectional view of an arrangement of a flavor pod;

FIG. 92 shows in detail parts of another arrangement of a smoking substitute system;

FIG. 93 shows detail of the heater and the heater support in the arrangement of FIG. 92;

FIG. 94 shows another arrangement of a smoking substitute system;

FIG. 95 shows detail of part of a smoking substitute system;

FIG. 96 shows detail of a heater support which may be used in a smoking substitute system;

FIG. 97 shows detail of an alternative heater support which may be used in a smoking substitute system;

FIG. 98 shows detail of a heater which may be used in a smoking substitute system;

FIG. 99 shows yet another arrangement of a smoking substitute system;

FIG. 100 shows a detailed schematic sectional view of a part of a smoking substitute system;

FIG. 101 shows yet another arrangement of a smoking substitute system;

FIG. 102 shows a consumable part of another smoking substitute system;

FIG. 103 shows another consumable part of a smoking substitute system;

and

FIG. 104 shows detail of the consumable part of FIG. 103.

DETAILED DESCRIPTION

First Mode: A fluid-transfer article in which part of the region which holds the aerosol precursor is in the form of a flexible diaphragm.

Aspects and embodiments of the first mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

In general outline, one or more embodiments in accordance with the first mode of the present disclosure may provide a system for aerosol delivery in which an aerosol carrier may be inserted into a receptacle (e.g., a “heating chamber”) of an apparatus for initiating and maintaining release of an aerosol from the aerosol carrier.

Another end, or another end portion, of the aerosol carrier may protrude from the apparatus and can be inserted into the mouth of a user for the inhalation of aerosol released from the aerosol carrier cartridge during operation of the apparatus.

Hereinafter, and for convenience only, “system for aerosol delivery” shall be referred to as “aerosol delivery system”.

Referring now to FIG. 1, there is illustrated a perspective view of an aerosol delivery system 10 comprising an aerosol generation apparatus 12 operative to initiate and maintain release of aerosol from a fluid-transfer article in an aerosol carrier 14. In the arrangement of FIG. 1, the aerosol carrier 14 is shown with a first end 16 thereof and a portion of the length of the aerosol carrier 14 located within a receptacle of the apparatus 12. A remaining portion of the aerosol carrier 14 extends out of the receptacle. This remaining portion of the aerosol carrier 14, terminating at a second end 18 of the aerosol carrier, is configured for insertion into a user's mouth. A vapor and/or aerosol is produced when a heater (not shown in FIG. 1) of the apparatus 12 heats a fluid-transfer article in the aerosol carrier 14 to release a vapor and/or an aerosol, and this can be delivered to the user, when the user sucks or inhales, via a fluid passage in communication with an outlet of the aerosol carrier 14 from the fluid-transfer article to the second end 18.

The apparatus 12 also comprises air-intake apertures 20 in the housing of the apparatus 12 to provide a passage for air to be drawn into the interior of the apparatus 12 (when the user sucks or inhales) for delivery to the first end 16 of the aerosol carrier 14, so that the air can be drawn across an activation surface of a fluid-transfer article located within a housing of the aerosol carrier 14 during use. Optionally, these apertures may be perforations in the housing of the apparatus 12. A fluid-transfer article (not shown in FIG. 1 but described hereinafter with reference to FIGS. 5 to 8 is located within a housing of the aerosol carrier 14. The fluid-transfer article contains an aerosol precursor material, which may include at least one of: nicotine; a nicotine precursor material; a nicotine compound; and one or more flavorings. The fluid-transfer article is located within the housing of the aerosol carrier 14 to allow air drawn into the aerosol carrier 14 at, or proximal, the first end 16 to flow across an activation surface of the fluid-transfer article. As air passes across the activation surface of the fluid-transfer article, an aerosol may be entrained in the air stream from a substrate forming the fluid-transfer article, e.g., via diffusion from the substrate to the air stream and/or via vaporization of the aerosol precursor material and release from the fluid-transfer article under heating. The substrate forming the fluid-transfer article 34 comprises a porous material where pores of the porous material hold, contain, carry, or bear the aerosol precursor material. In particular, the porous material of the fluid-transfer article may be a polymeric wicking material such as, for example, a sintered material. Particular examples of material suitable for the fluid-transfer article include: Polyetherimide (PEI); Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK); Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular Weight Polyethylene. Other suitable materials may comprise, for example, BioVyon™ (by Porvair Filtration Group Ltd) and materials available from Porex®. Further optionally, a substrate forming the fluid-transfer article may comprise Polypropylene (PP) or Polyethylene Terephthalate (PET). All such materials may be described as heat resistant polymeric wicking material in the context of the first mode of the present disclosure.

The aerosol carrier 14 is removable from the apparatus 12 so that it may be disposed of when expired. After removal of a used aerosol carrier 14, a replacement aerosol carrier 14 can be inserted into the apparatus 12 to replace the used aerosol carrier 14.

FIG. 2 is a cross-sectional side view illustration of a part of apparatus 12 of the aerosol delivery system 10. The apparatus 12 comprises a receptacle 22 in which is located a portion of the aerosol carrier 14. In one or more optional arrangements, the receptacle 22 may enclose the aerosol carrier 14. The apparatus 12 also comprises a heater 24, which opposes an activation surface of the fluid-transfer article (not shown in FIG. 2) of the aerosol carrier 14 when the aerosol carrier 14 is located within the receptacle 22. Air flows into the apparatus 12 (in particular, into a closed end of the receptacle 22) via air-intake apertures 20. From the closed end of the receptacle 22, the air is drawn into the aerosol carrier 14 (under the action of the user inhaling or sucking on the second end 18) and expelled at the second end 18. As the air flows into the aerosol carrier 14, it passes across the activation surface of the fluid-transfer article. Heat from the heater 24, which opposes the activation surface of the fluid-transfer article, causes vaporization of aerosol precursor material at the activation surface of the fluid-transfer article and an aerosol is created in the air flowing over the activation surface. Thus, through the application of heat in the region of the activation surface of the fluid-transfer article, an aerosol is released, or liberated, from the fluid-transfer article, and is drawn from the material of the aerosol carrier unit by the air flowing across the activation surface and is transported in the air flow to via outlet conduits (not shown in FIG. 2) in the housing of the aerosol carrier 14 to the second end 18. The direction of air flow is illustrated by arrows in FIG. 2.

To achieve release of the captive aerosol from the fluid-transfer article, the fluid-transfer article of the aerosol carrier 14 is heated by the heater 24. As a user sucks or inhales on second end 18 of the aerosol carrier 14, the aerosol released from the fluid-transfer article and entrained in the air flowing across the activation surface of the fluid-transfer article is drawn through the outlet conduits (not shown) in the housing of the aerosol carrier 14 towards the second end 18 and onwards into the user's mouth. Turning now to FIG. 3, a cross-sectional side view of the aerosol delivery system 10 is schematically illustrated showing the features described above in relation to FIGS. 1 and 2 in more detail. As can be seen, apparatus 12 comprises a housing 26, in which are located the receptacle 22 and heater 24. The housing 26 also contains control circuitry (not shown) operative by a user, or upon detection of air and/or vapor being drawn into the apparatus 12 through air-intake apertures 20, i.e., when the user sucks or inhales. Additionally, the housing 26 comprises an electrical energy supply 28, for example a battery. Optionally, the battery comprises a rechargeable lithium-ion battery. The housing 26 also comprises a coupling 30 for electrically (and optionally mechanically) coupling the electrical energy supply 28 to control circuitry (not shown) for powering and controlling operation of the heater 24. Responsive to activation of the control circuitry of apparatus 12, the heater 24 heats the fluid-transfer article (not shown in FIG. 3) of aerosol carrier 14. This heating process initiates (and, through continued operation, maintains) release of vapor and/or an aerosol from the activation surface of the fluid-transfer article. The vapor and/or aerosol formed as a result of the heating process is entrained into a stream of air being drawn across the activation surface of the fluid-transfer article (as the user sucks or inhales). The stream of air with the entrained vapor and/or aerosol passes through the aerosol carrier 14 via outlet conduits (not shown) and exits the aerosol carrier 14 at second end 18 for delivery to the user. This process is briefly described above in relation to FIG. 2, where arrows schematically denote the flow of the air stream into the apparatus 12 and through the aerosol carrier 14, and the flow of the air stream with the entrained vapor and/or aerosol through the aerosol carrier 14.

FIGS. 4 to 6 schematically illustrate the aerosol carrier 14 in more detail (and, in FIGS. 5 and 6, features within the receptacle in more detail). FIG. 4 illustrates an exterior of the aerosol carrier 14, FIG. 5 illustrates internal components of the aerosol carrier 14 in an optional configuration, and FIG. 6 illustrates internal components of the aerosol carrier 14 in another optional configuration.

FIG. 4 illustrates the exterior of the aerosol carrier 14, which comprises housing 32 for housing said fluid-transfer article (not shown) and at least one other internal component. The particular housing 32 illustrated in FIG. 4 comprises a tubular member, which may be generally cylindrical in form, and which is configured to be received within the receptacle of the apparatus. First end 16 of the aerosol carrier 14 is for location to oppose the heater of the apparatus, and second end 18 (and the region adjacent the second end 18) is configured for insertion into a user's mouth.

FIGS. 5 and 6 illustrates some internal components of the aerosol carrier 14 and of the heater 24 of apparatus 12, in one embodiment of the first mode.

As described above, the aerosol carrier 14 comprises a fluid-transfer article 34. Optionally, there may be a conduction element 37 (as shown in FIG. 5), being part of the heater 24. In one or more arrangements, the aerosol carrier 14 is located within the receptacle of the apparatus such that the activation surface of the fluid-transfer article opposes the heater 24 of the apparatus and receives heat directly from the heater 24 of the apparatus. When aerosol carrier 14 is located within the receptacle of the apparatus such that the activation surface of the fluid-transfer article is located to oppose the heater of the apparatus, the conduction element 37 is disposed between the rest of the heater 24 and the activation surface of the fluid-transfer article. Heat may be transferred to the activation surface via conduction through conduction element 37 (i.e., application of heat to the activation surface is indirect).

Further components not shown in FIGS. 5 and 6 comprise: an inlet conduit, via which air can be drawn into the aerosol carrier 14; an outlet conduit, via which an air stream entrained with aerosol can be drawn from the aerosol carrier 14; a filter element; and a reservoir for storing aerosol precursor material and for providing the aerosol precursor material to the fluid-transfer article 34.

In FIGS. 5 and 6, the aerosol carrier is shown as comprising the fluid-transfer article 34 located within housing 32. The fluid-transfer article 34 comprises a first region 35 holding an aerosol precursor. In one or more arrangements, the first region 35 of the fluid-transfer article 34 comprises a reservoir for holding the aerosol precursor. The first region 35 can be the sole reservoir of the aerosol carrier 14, or it can be arranged in fluid communication with a separate reservoir, where aerosol precursor is stored for supply to the first region 35. As shown in FIGS. 5 and 6, the material forming the first region 35 comprises a porous structure, whose pore diameter size varies between one end of the first region 35 and another end of the first region 35. In the illustrated examples of FIGS. 5 and 6, the pore diameter size decreases from a first end remote from heater 24 (the upper end is as shown in the figure) to a second end. Although the figure illustrates the pore diameter size changing in a stepwise manner (i.e., a first part with pores having a diameter of first size, and a second part with pores having a diameter of second, smaller size), the change in pore size in the first region 35 may be gradual rather than step-wise. This configuration of pores having a decreasing diameter size can provide a wicking effect, which can serve to draw fluid through the first region 35, towards heater 24.

The fluid-transfer article 34 also comprises a second region 36. Aerosol precursor is drawn from the first region 35 to the second region 36 by the wicking effect of the material forming the first region 35. Thus, the first region 35 is configured to transfer the aerosol precursor to the second region 36 of the fluid-transfer article 34.

The second region 36 may itself comprise a porous structure. It is then preferable that the pore diameter size of the porous structure of the second region 36 is smaller than the pore diameter size of the immediately adjacent part of the first region 35.

In FIGS. 5 and 6, the second region 36 is in the form of a flexible diaphragm. That flexible diaphragm is biased towards the position shown in FIG. 5, which is convex towards the conduction element and such that a part of the second region 36 is in contact with the conduction element 37. The surface of the second region 36 which is closest to the conduction element 37 is the activation surface.

FIGS. 5 and 6 also illustrate an opening 38 in the housing 32, which opening 38 is in fluid communication with the air-intake apertures 20. A further opening 39 communicates with a duct 40 within the housing 32, which duct 40 communicates with the second end 18.

There is thus a fluid-flow path for air (hereinafter referred to as an air-flow pathway) between openings 38 and 39, linking the air-intake apertures 20 and the second end 18 of the aerosol carrier. In the arrangement shown in FIG. 5, that air-flow pathway is blocked by the second region 36, due to its contact with the conduction element 37. However, when the user sucks or inhales, air is drawn along the air-flow pathway and the second region 36 flexes away from the conduction element 37 to the position shown in FIG. 6. Air may then pass along the surface of the conduction element 37, between the conduction element 37 and the second region 36.

The mechanism for this is believed to be as follows. In the position shown in FIG. 5, some of the aerosol precursor which as passed to the second region 36 will contact or “pool” on the conduction element 37. When a user inhales, low pressure is created in the duct 40 and hence a low-pressure region is formed adjacent the second region 36, This will cause the second region 36 to deform from the position shown in FIG. 6, thereby creating an air-flow path between the second region 36 and the conduction element 37. Since the heater 24 is activated at this time, the aerosol precursor which has pooled on the conduction element 37 will be vaporized and pass into the air flow in the air-flow pathway. Once the user ceases to inhale, the second region 36 returns to the position shown in FIG. 5, thereby allowing more aerosol precursor to pool on the conduction element 37.

Thus, as the second region 36 moves away from the conduction element 37, one or more droplets of the aerosol precursor will be deposited on the conduction element and be heated, to release vapor or a mixture of aerosol and vapor from the conduction element 37 into the air flowing in the air-flow pathway between the openings 38, 39. The vapor or mixture passes, as the user sucks and inhales, to the second end 18. The configuration of the second region 36 may be chosen so as to deposit a specific amount of liquid on the conduction element 37 each time the second region 36 moves from the position shown in FIG. 5 to the position shown in FIG. 6, to ensure consistent amounts of vapor and/or a mixture of vapor and aerosol getting into the airflow. Once the user desists to inhale or suck, the airflow will stop and the second region 36 will return to the position shown in FIG. 5 from the position shown in FIG. 6 Hence the second region 36 is in contact with the conduction element 37 when there is no air flow, and the conduction element 37 will at least partially obstruct the end of the fluid-transfer article 34, reducing or preventing leakage of fluid from the fluid-transfer article 34 when the aerosol delivery system is not being actively used by the user.

As noted above, the conduction element 37 may be absent in some arrangements.

The conduction element 37, if present, may comprise a thin film of thermally conductive material, such as, for example, a metal foil (for example, aluminum, brass, copper, gold, steel, silver, or an alloy comprising anyone of the foregoing together with thermally conductive plastics and/or ceramics).

In the illustrative examples of FIGS. 5 and 6, the first region 35 of the fluid-transfer article 34 is located at an “upstream” end of the fluid-transfer article 34 and the second region 36 is located at a downstream” end of the fluid-transfer article 34. That is, aerosol precursor is wicked, or is drawn, from the “upstream” end of the fluid-transfer article 34 to the “downstream” end of the fluid-transfer article 34 (as denoted by arrow A in FIG. 5).

In the arrangement shown in FIGS. 5 and 6, the openings 38 and 39 are on opposite sides of the housing 32. FIGS. 7 and 8 show an alternative configuration, in which the fluid-transfer article is annular, and the second region 36 is then in the form of annular diaphragm. In FIGS. 7 and 8, the second region 36 is illustrated in a position corresponding to that shown in FIG. 6, where it is spaced from the conduction element 37. This enables the air flow in the apparatus to be illustrated. However, as in the arrangement of FIGS. 5 and 6, when there is no air flow the second region 36 takes up a configuration in which it is generally convex towards and in contact with the conduction element 37, that contact being itself annular. Thus, FIGS. 7 and 8 illustrate an aerosol carrier 14 according to one or more possible arrangements in more detail. FIG. 7 is a cross-section side view illustration of the aerosol carrier 14 and FIG. 8 is a perspective cross-section side view illustration of the aerosol carrier 14.

As can be seen from FIGS. 7 and 8, the aerosol carrier 14 is generally tubular in form. The aerosol carrier 14 comprises housing 32, which defines the external walls of the aerosol carrier 14 and which defines therein a chamber in which are disposed the fluid-transfer article 34 (adjacent the first end 16 of the aerosol carrier 14) and internal walls defining the fluid communication pathway 48. Fluid communication pathway 48 defines a fluid pathway for an outgoing air stream from the ducts 40 to the second end 18 of the aerosol carrier 14. In the examples illustrated in FIGS. 7 and 8, the fluid-transfer article 34 is an annular shaped element located around the fluid communication pathway 48.

In walls of the housing 32, there are provided inlet apertures 50 to provide a fluid communication pathway for an incoming air stream to reach the fluid-transfer article 34, and particularly the one or more ducts 40 defined between the activation surface of the fluid-transfer article 34 and the conduction element 37 (or between the activation surface and the heater).

In the illustrated example of FIGS. 7 and 8, the aerosol carrier 14 further comprises a filter element 52. The filter element 52 is located across the fluid communication pathway 48 such that an outgoing air stream passing through the fluid communication pathway 48 passes through the filter element 52. With reference to FIG. 8, when a user sucks on a mouthpiece of the apparatus (or on the second end 18 of the aerosol carrier 14, if configured as a mouthpiece), air is drawn into the carrier through inlet apertures 50 extending through walls in the housing 32 of the aerosol carrier 14. As in the embodiment of FIGS. 5 and 6, this causes the diaphragm formed by the second region 36 to move to a position in which it is separated from the conduction element 37 and an air-flow pathway, passing between the conduction element 37 and the diaphragm is open.

An incoming air stream 42 from a first side of the aerosol carrier 14 is directed to a first side of the second region 36 of the fluid-transfer article 34 (e.g., via a gas communication pathway within the housing of the carrier). An incoming air stream 43 from a second side of the aerosol carrier 14 is directed to a second side of the first region 35 of the fluid-transfer article 34 (e.g., via a gas communication pathway within the housing of the carrier). When the incoming air stream 42 from the first side of the aerosol carrier 14 reaches the first side of the second region 36, the incoming air stream 42 from the first side of the aerosol carrier 14 flows between the second region 36 and the conduction element 37 (or between the second region 36 and heater 24). Likewise, when the incoming air stream 43 from the second side of the aerosol carrier 14 reaches the second side of the second region 36, the incoming air stream 43 from the second side of the aerosol carrier 14 flows between the second region 36 and the conduction element 37 (or between the second region 36 and heater 24). The air streams from each side are denoted by dashed lines 44 and 45 in FIG. 8 As these air streams 44 and 45 flow, aerosol precursor on the conduction element 37 (or on the heater 24) is entrained in air streams 44 and 45. In use, the heater 24 of the apparatus 12 serves to raise a temperature of the conduction element 37 to a sufficient temperature to release, or liberate, captive substances (i.e., the aerosol precursor) to form a vapor and/or aerosol, which is drawn downstream. As the air streams 44 and 45 continue their passages, more released aerosol precursor is entrained within the air streams 44 and 45. When the air streams 44 and 45 entrained with aerosol precursor meet at a mouth of the outlet fluid communication pathway 48, they enter the outlet fluid communication pathway 48 and continue until they pass through filter element 52 and exit outlet fluid communication pathway 48, either as a single outgoing air stream, or as separate outgoing air streams 46 (as shown). The outgoing air streams 46 are directed to an outlet, from where it can be inhaled by the user directly (if the second end 18 of the aerosol carrier 14 is configured as a mouthpiece), or via a mouthpiece. The outgoing air streams 46 entrained with aerosol precursor are directed to the outlet (e.g., via a gas communication pathway within the housing of the carrier).

FIG. 9 is an exploded perspective view illustration of a kit-of-parts for assembling an aerosol delivery system 10.

In any of the embodiments of the first mode described above the second region 36 may have a thickness of less than 5 mm. In other embodiments of the first mode it may have a thickness of: less than 3.5 mm, less than 3 mm, less than 2.5 mm, less than 2 mm, less than 1.9 mm, less than 1.8 mm, less than 1.7 mm, less than 1.6 mm, less than 1.5 mm, less than 1.4 mm, less than 1.3 mm, less than 1.2 mm, less than 1.1 mm, less than 1 mm, less than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less than 0.6 mm, less than 0.5 mm, less than 0.4 mm, less than 0.3 mm, less than 0.2 mm, or less than 0.1 mm.

As will be appreciated, in the arrangements described above, the fluid-transfer article 34 is provided within a housing 32 of the aerosol carrier 14. In such arrangements, the housing of the aerosol carrier 14 serves to protect the aerosol precursor-containing fluid-transfer article 34, whilst also allowing the aerosol carrier 14 to be handled by a user without his/her fingers coming into contact with the aerosol precursor liquid retained therein.

Second Mode: An aerosol-generation apparatus having a heater, at least part of which deforms or moves during use.

Aspects and embodiments of the second mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

In general outline, one or more embodiments in accordance with the second mode of the present disclosure may provide a system for aerosol delivery in which an aerosol carrier may be inserted into a receptacle (e.g., a “heating chamber”) of an apparatus for initiating and maintaining release of an aerosol from the aerosol carrier. Another end, or another end portion, of the aerosol carrier may protrude from the apparatus and can be inserted into the mouth of a user for the inhalation of aerosol released from the aerosol carrier cartridge during operation of the apparatus.

Hereinafter, and for convenience only, “system for aerosol delivery” shall be referred to as “aerosol delivery system”.

Referring now to FIG. 10, there is illustrated a perspective view of an aerosol delivery system 10 b comprising an aerosol generation apparatus 12 b operative to initiate and maintain release of aerosol from a fluid-transfer article in an aerosol carrier 14 b. In the arrangement of FIG. 10, the aerosol carrier 14 b is shown with a first end 16 b thereof and a portion of the length of the aerosol carrier 14 b located within a receptacle of the apparatus 12 b. A remaining portion of the aerosol carrier 14 b extends out of the receptacle. This remaining portion of the aerosol carrier 14 b, terminating at a second end 18 b of the aerosol carrier, is configured for insertion into a user's mouth. A vapor and/or aerosol is produced when a heater (not shown in FIG. 10) of the apparatus 12 b heats a fluid-transfer article in the aerosol carrier 14 b to release a vapor and/or an aerosol, and this can be delivered to the user, when the user sucks or inhales, via a fluid passage in communication with an outlet of the aerosol carrier 14 b from the fluid-transfer article to the second end 18 b.

The apparatus 12 also comprises air-intake apertures 20 b in the housing of the apparatus 12 b to provide a passage for air to be drawn into the interior of the apparatus 12 b (when the user sucks or inhales) for delivery to the first end 16 b of the aerosol carrier 14 b, so that the air can be drawn across an activation surface of a fluid-transfer article located within a housing of the aerosol carrier 14 b during use. Optionally, these apertures may be perforations in the housing of the apparatus 12 b.

A fluid-transfer article (not shown in FIG. 10 but described hereinafter with reference to subsequent drawings) is located within a housing of the aerosol carrier 14 b. The fluid-transfer article contains an aerosol precursor material, which may include at least one of: nicotine; a nicotine precursor material; a nicotine compound; and one or more flavorings. The fluid-transfer article is located within the housing of the aerosol carrier 14 b to allow air drawn into the aerosol carrier 14 b at, or proximal, the first end 16 b to flow across an activation surface of the fluid-transfer article. As air passes across the activation surface of the fluid-transfer article, an aerosol may be entrained in the air stream from a substrate forming the fluid-transfer article, e.g., via diffusion from the substrate to the air stream and/or via vaporization of the aerosol precursor material and release from the fluid-transfer article under heating. The substrate forming the fluid-transfer article 33 b comprises a porous material where pores of the porous material hold, contain, carry, or bear the aerosol precursor material. In particular, the porous material of the fluid-transfer article may be a polymeric wicking material such as, for example, a sintered material. Particular examples of material suitable for the fluid-transfer article include: Polyetherimide (PEI); Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK); Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular Weight Polyethylene. Other suitable materials may comprise, for example, BioVyon™ (by Porvair Filtration Group Ltd) and materials available from Porex®. Further optionally, a substrate forming the fluid-transfer article may comprise Polypropylene (PP) or Polyethylene Terephthalate (PET). All such materials may be described as heat resistant polymeric wicking material in the context of the second mode of the present disclosure. The aerosol carrier 14 b is removable from the apparatus 12 b so that it may be disposed of when expired. After removal of a used aerosol carrier 14 b, a replacement aerosol carrier 14 b can be inserted into the apparatus 12 b to replace the used aerosol carrier 14 b.

FIG. 11 is a cross-sectional side view illustration of a part of apparatus 12 b of the aerosol delivery system 10 b. The apparatus 12 b comprises a receptacle 22 b in which is located a portion of the aerosol carrier 14 b. In 25 one or more optional arrangements, the receptacle 22 b may enclose the aerosol carrier 14 b. The apparatus 12 b also comprises a heater 24 b, which opposes an activation surface of the fluid-transfer article (not shown in FIG. 11) of the aerosol carrier 14 b when an aerosol carrier 14 b is located within the receptacle 22 b.

Air flows into the apparatus 12 b (in particular, into a closed end of the receptacle 22 b) via air-intake apertures 20 b. From the closed end of the receptacle 22 b, the air is drawn into the aerosol carrier 14 b (under the action of the user inhaling or sucking on the second end 18 b) and expelled at the second end 18 b. As the air flows into the aerosol carrier 14 b, it passes across the activation surface of the fluid-transfer article. Heat from the heater 24 b, which opposes the activation surface of the fluid-transfer article, causes vaporization of aerosol precursor material at the activation surface of the fluid-transfer article and an aerosol is created in the air flowing over the activation surface. Thus, through the application of heat in the region of the activation surface of the fluid-transfer article, an aerosol is released, or liberated, from the fluid-transfer article, and is drawn from the material of the aerosol carrier unit by the air flowing across the activation surface and is transported in the air flow via outlet conduits (not shown in FIG. 11) in the housing of the aerosol carrier 14 b to the second end 18 b. The direction of air flow is illustrated by arrows in FIG. 11.

To achieve release of the captive aerosol from the fluid-transfer article, the fluid-transfer article of the aerosol carrier 14 b is heated by the heater 24 b. As a user sucks or inhales on second end 18 b of the aerosol carrier 14 b, the aerosol released from the fluid-transfer article and entrained in the air flowing across the activation surface of the fluid-transfer article is drawn through the outlet conduits (not shown) in the housing of the aerosol carrier 14 b towards the second end 18 b and onwards into the user's mouth.

Turning now to FIG. 12, a cross-sectional side view of the aerosol delivery system 10 b is schematically illustrated showing the features described above in relation to FIGS. 10 and 11 in more detail. As can be seen, apparatus 12 b comprises a housing 26 b, in which are located the receptacle 22 b and heater 24 b. The housing 26 b also contains control circuitry (not shown) operative by a user, or upon detection of air and/or vapor being drawn into the apparatus 12 through air-intake apertures 20 b, i.e., when the user sucks or inhales. Additionally, the housing 26 b comprises an electrical energy supply 28 b, for example a battery. Optionally, the battery comprises a rechargeable lithium-ion battery. The housing 26 b also comprises a coupling 30 b for electrically (and optionally mechanically) coupling the electrical energy supply 28 b to control circuitry (not shown) for powering and controlling operation of the heater 24 b.

Responsive to activation of the control circuitry of apparatus 12 b, the heater 24 b heats the fluid-transfer article (not shown in FIG. 12) of aerosol carrier 14 b. This heating process initiates (and, through continued operation, maintains) release of vapor and/or an aerosol from the activation surface of the fluid-transfer article. The vapor and/or aerosol formed as a result of the heating process is entrained into a stream of air being drawn across the activation surface of the fluid-transfer article (as the user sucks or inhales). The stream of air with the entrained vapor and/or aerosol passes through the aerosol carrier 14 b via outlet conduits (not shown) and exits the aerosol carrier 14 b at the second end 18 b for delivery to the user. This process is briefly described above in relation to FIG. 11, where arrows schematically denote the flow of the air stream into the apparatus 12 and through the aerosol carrier 14 b, and the flow of the air stream with the entrained vapor and/or aerosol through the aerosol carrier 14 b.

FIGS. 13 to 16 schematically illustrate the aerosol carrier 14 b in more detail (and, in FIGS. 14 to 16, features within the receptacle in more detail). FIG. 14 illustrates internal components of the aerosol carrier 14 b in one configuration at one temperature, and FIGS. 15 and 16 illustrate internal components of the aerosol carrier 14 b in another configuration at another temperature.

FIG. 4 illustrates the exterior of the aerosol carrier 14 b, which comprises housing 32 b for housing said fluid-transfer article (not shown) and at least one other internal component. The particular housing 32 b illustrated in FIG. 13 comprises a tubular member, which may be generally cylindrical in form, and which is configured to be received within the receptacle of the apparatus. First end 16 b of the aerosol carrier 14 b is for location to oppose the heater of the apparatus, and second end 18 b (and the region adjacent the second end 18 b) is configured for insertion into a user's mouth.

FIGS. 14 to 16 illustrate some internal components of the aerosol carrier 14 b and of the heater 24 b of apparatus 12 b.

As described above, the aerosol carrier 14 b comprises a fluid-transfer article 33 b. Optionally, there may be a conduction element 36 b (as shown in FIG. 14) being part of the heater 24 b. In one or more arrangements, the aerosol carrier 14 b is located within the receptacle of the apparatus such that the activation surface of the fluid-transfer article opposes the heater of the apparatus and receives heat directly from the heater of the apparatus. When aerosol carrier 14 b is located within the receptacle of the apparatus such that the activation surface 35 b of the fluid-transfer article is located to oppose the heater 24 b of the apparatus, the conduction element 36 b is disposed between the rest of the heater 24 b and the activation surface of the fluid-transfer article. Heat may be transferred to the activation surface via conduction through conduction element 36 b (i.e., application of heat to the activation surface is indirect).

Further components not shown in FIGS. 14 to 16 comprise: an inlet conduit, via which air can be drawn into the aerosol carrier 14 b; an outlet conduit, via which an air stream entrained with aerosol can be drawn from the aerosol carrier 14 b; a filter element; and a reservoir for storing aerosol precursor material and for providing the aerosol precursor material to the fluid-transfer article 33 b.

In FIGS. 14 to 16, the aerosol carrier is shown as comprising the fluid-transfer article 33 b located within a housing 32 b. The fluid-transfer article 33 b comprises a first region 34 b holding an aerosol precursor. In one or more arrangements, the first region 34 b of the fluid-transfer article 33 b comprises a reservoir for holding the aerosol precursor. The first region 34 b can be the sole reservoir of the aerosol carrier 14 b, or it can be arranged in fluid communication with a separate reservoir, where aerosol precursor is stored for supply to the first region 34 b. As shown in FIGS. 14 to 16, the material forming the first region 34 b comprises a porous structure, whose pore diameter size varies between one end of the first region 34 b and another end of the first region 34 b. In the illustrated examples of FIGS. 14 to 16, the pore diameter size decreases from a first end remote from heater 24 b (the upper end is as shown in the figure) to a second end. Although the figure illustrates the pore diameter size changing in a stepwise manner (i.e., a first part with pores having a diameter of first size, and a second part with pores having a diameter of second, smaller size), the change in pore size in the first region 34 b may be gradual rather than step-wise. This configuration of pores having a decreasing diameter size can provide a wicking effect, which can serve to draw fluid through the first region 34 b, towards heater 24 b. The fluid-transfer article 33 b also comprises a second region 35 b. Aerosol precursor is drawn from the first region 34 b to the second region 35 b by the wicking effect of the material forming the first region 34 b. Thus, the first region 34 b is configured to transfer the aerosol precursor to the second region 35 b of the article 33 b. The second region 35 b terminates in an activation surface 35 b, which is the surface facing the heater 24 b. The second region 35 b may itself comprise a porous structure. It is then preferable that the pore diameter size of the porous structure of the second region 35 b is smaller than the pore diameter size of the immediately adjacent part of the first region 34 b.

The first region 34 b of the fluid-transfer article need not be of porous polymer material as described above. It may instead be a simple hollow reservoir filled with liquid aerosol precursor. The liquid aerosol precursor will then pass directly from the first region 34 b to the second region 35 b. Similarly, the second region 35 b, need not be of porous polymer material. Instead, it may be of any material with a ‘wicking’ action which will transfer aerosol precursor from the first region 34 b to the activation surface 35 b, for example a fibrous wick.

FIG. 14 then illustrates the configuration of the device at a first temperature, such as room temperature. As shown in FIG. 14, in this configuration the heater 24 b occupies a position such that conduction element 36 b is in contact, or immediately adjacent, the activation surface 35 b of the second region 35 b, and there is a gap 41 b between the heater 24 b and the coupling 30 b. The housing 32 b has an opening 38 b therein, which may receive air from the apertures 20 b, and another opening 39 b leading to a duct 40 b within the housing 32 b, which duct 40 b leads to the second upstream end 18 b of the aerosol carrier 14 b. Thus, in the position shown in FIG. 14, air can pass from the apertures 20 b through the opening 38 b into the gap 37 b between the heater 24 b and the coupling 30 b and from the gap 41 b through the opening 38 b into the duct 40 b and hence to the second end 18 b. That air flow is obstructed by the heater 24 b from reaching the activation surface 35 b.

In the position shown in FIG. 14, the parts of the periphery of the heater 24 b visible in the Figure are not attached to the housing 32 b and are free to move. On the other hand, the parts of the periphery of the heater 24 b perpendicular to the view of FIG. 14 are attached to the housing 32 b, or to a mechanical barrier or seating adjacent the housing 32 b, to hold those parts of the periphery of the heater 24 b in place. When the heater 24 b is activated, it will heat up. The materials of the heater 24 b, including the conduction element 36 b, are chosen so that they expand under such heating, and so the heater 24 b, including the conduction element 36 b, will deform as part of its periphery is held in position and part is free to move. In particular, the heater 24 b will deform from the position shown in FIG. 14 to the position shown in FIG. 15, with the view of FIG. 15 being perpendicular to the view of FIG. 14 The effect of this deformation is to create a space 42 b between the conduction element 36 b and the activation surface 35 b, which space 42 b is in communication with the openings 38 b and 39 b (the openings not being visible in FIG. 15). Thus, space 42 b now forms part of an air-flow pathway between the openings 38 b and 39 b, which air-flow pathway passes between the activation surface 35 b and the conduction element 36 b.

FIG. 15 illustrates how, because parts of the periphery of the heater 24 b are held in place due to their attachment to the housing 32 b or by a mechanical barrier or seating, the heater 24 b adopts a domed shape perpendicular to the view in FIG. 14 FIG. 16 shows a view perpendicular to FIG. 15, to illustrate that the space 42 b communicates with the openings 38 b and 39 b. Thus, the movement of the heater between the position shown in FIG. 14, and the position shown in FIGS. 15 and 16, has the effect of unblocking, or removing the obstruction from, the air-flow pathway extending between the opening 38 b and the opening 39 b which passes between the activation surface 35 b and the conduction element 36 b of the heater 24 b. In the obstructed position of FIG. 14, the heater 24 b prevents aerosol precursor reaching any air flowing between the openings 38 b and 39 b, whereas in the position shown in FIGS. 15 and 16, the activation surface 35 b is exposed to air flowing between the openings 38 b and 39 b.

When the device is not being used, and the heater 24 b is in the position shown in FIG. 14, aerosol precursor will pass to the activation surface 35 b, and be deposited on the heater 24 b if there is any clearance between the conduction element 36 b and the activation surface 35 b, or at least be in contact with the conduction element 36 b if there is no such clearance, and the conduction element 36 b is in contact with the activation surface 35 b. When the device is in use, and the heater heats up, such aerosol precursor at the activation surface, or on the conduction element 36 b, will be heated by the heat generated by the heater 24 b, and vaporized in the space 42 b. That vapor, or a mixture of aerosol and vapor, will then mix with air flowing between the openings 38 b and 39 b through the space 42 b as the user draws on the mouthpiece at end 18 b, and air and the vapor or mixture of vapor and aerosol will pass through the opening 39 b, and through the duct 40 b, to the end 18 b, and hence to the user.

Thus, droplets of aerosol precursor will be transferred from the second part 35 b of the fluid-transfer article to the conduction element 36 b, and move away from the activation surface 35 b as the heater 24 b changes from the position shown in FIG. 14 to the position shown in FIGS. 15 and 16. Those droplets of aerosol precursor will then be wholly or partially vaporized by the elevated temperature of the conduction element 36 b, with additional aerosol precursor passing from the activation surface 35 b into the space 42 b also being vaporized. In practice, aerosol precursor may “pool” in the space 42 b, until it is vaporized, although the amount of aerosol precursor which is on the conduction element 36 b or in the space 42 b is preferably determined so that substantially all of it will be vaporized when the heater 24 b is active.

Thus, the configuration of the second region 35 b of the fluid-transfer article may be chosen so as to deposit a specific amount of aerosol precursor on the conduction element 36 b when the conduction element 36 b is in the position shown in FIG. 14, to ensure consistent amounts of vapor and/or a mixture of vapor and aerosol getting into the air flow.

Once the user desists to inhale or suck, the air flow will stop. The heater may be allowed to cool in this state, to return to the position shown in FIG. 14 from the position shown in FIG. 15 so that there is a cyclic operation with the air-flow pathway between the activation surface 35 b and the conduction element 36 b being closed or open (obstructed or un-obstructed) through a cycle of inhalations by the user. Alternatively, the heater 24 b may remain heated between inhalations by the user, with the space 42 b being filled with vaporized aerosol precursor between inhalations.

The materials of the heater 24 b, including the conduction element 36 b, are preferably chosen such that their thermal expansion is consistent, allowing there to be a known relationship between the temperature of the heater 24 b and the distance the central part of the heater 24 b moves away from the activation surface 35 b. In this way, the distance between the activation surface 35 b and the conduction element 36 b, and hence the size of the air-flow pathway between the activation surface 35 b and conduction element 36 b, can be chosen to achieve a satisfactory volumetric flow rate when the user inhales. Attachment of parts of the periphery of the heater 24 b to the housing 32 b, and the non-attachment of other parts of the periphery, allows the heater to “dome” as illustrated in FIG. 15, to open or un-obstruct the air-flow pathway between the activation surface 35 b and the conduction element 36 b.

As noted above, the conduction element 36 b may be absent in some arrangements, in which case the second part 35 b of the fluid-transfer article will receive heat directly from the heater 24 b.

Also, in the arrangements of FIGS. 14 to 16, the whole of the heater 24 b deforms as the temperature changes. It may be possible to have an arrangement in which only part of the heater, such as the conduction element 36 b, deforms as the temperature changes. In general, it is the heating surface of the heater which must deform to allow air to reach the space 42 b between the activation surface 35 b and the heater 24 b.

The conduction element 36 b, if present, may comprise a thin film of thermally conductive material, such as, for example, a metal foil (for example, aluminum, brass, copper, gold, steel, silver, or an alloy comprising anyone of the foregoing together with thermally conductive plastics and/or ceramics).

In the illustrative examples of FIGS. 14 to 16, the first region 34 b of the fluid-transfer article 33 b is located at an “upstream” end of the fluid-transfer article 33 b and the second region 35 b is located at a downstream” end of the fluid-transfer article 33 b. That is, aerosol precursor is wicked, or is drawn, from the “upstream” end of the fluid-transfer article 33 b to the “downstream” end of the fluid-transfer article 33 b (as denoted by arrow B in FIG. 14).

In the arrangement shown in FIGS. 14 to 16, the openings 38 b, 39 b are on opposite sides of the housing 32 b. FIGS. 17 and 18 show an alternative configuration, in which the fluid-transfer article is annular. In FIGS. 17 and 18, the heater 24 b, including the conduction element 36 b, is illustrated in a position corresponding to that shown in FIGS. 15 and 16, where the conduction element 36 b is spaced from the activation surface 35 b. This enables the air flow in the apparatus to be illustrated. However, as in the arrangement of FIGS. 14 to 16, when the heater is cool, the heater 24 b will move, so that the conduction element 36 b is in contact with, or is immediately adjacent, the activation surface 35 b. The deformation of the heater 24 b may have to be slightly greater than in FIG. 14, to ensure that it contacts, or is immediately adjacent, the activation surface 35 b, which itself is annular due to the annular configuration of the second part 35 b of the fluid-transfer article. The operation of the embodiment of the second mode of FIGS. 17 and 18 is otherwise similar to that of the embodiments of FIGS. 14 to 16.

Thus, FIGS. 17 and 18 illustrate an aerosol carrier 14 b according to one or more possible arrangements in more detail. FIG. 17 is a cross-section side view illustration of the aerosol carrier 14 b and FIG. 18 is a perspective cross-section side view illustration of the aerosol carrier 14 b. As can be seen from FIGS. 17 and 18, the aerosol carrier 14 b is generally tubular in form. The aerosol carrier 14 b comprises housing 32 b, which defines the external walls of the aerosol carrier 14 b and which defines therein a chamber in which are disposed the fluid-transfer article 33 b (adjacent the first end 16 b of the aerosol carrier 14 b) and internal walls defining the fluid communication pathway 48 b. Fluid communication pathway 48 b defines a fluid pathway for an outgoing air stream from the ducts 40 b to the second end 18 b of the aerosol carrier 14 b. In the examples illustrated in FIGS. 17 and 18, the fluid-transfer article 33 b is an annular shaped element located around the fluid communication pathway 48 b.

In walls of the housing 32 b, there are provided inlet apertures 50 b to provide a fluid communication pathway for an incoming air stream to reach the fluid-transfer article 33 b, and particularly the one or more ducts 40 b defined between the activation surface of the fluid-transfer article 33 b and the conduction element 36 b (or between the activation surface and the 15 heater). In the illustrated example of FIGS. 17 and 18, the aerosol carrier 14 b further comprises a filter element 52 b. The filter element 52 b is located across the fluid communication pathway 48 b such that an outgoing air stream passing through the fluid communication pathway 48 b passes through the filter element 52 b.

With reference to FIG. 17, when the heater is activated and a user sucks on a mouthpiece of the apparatus (or on the second end 18 b of the aerosol carrier 14 b, if configured as a mouthpiece), air is drawn into the carrier through inlet apertures 50 b extending through walls in the housing 32 b of the aerosol carrier 14 b. On activation of the heater, the conduction element 36 b will deform to move clear of the activation surface 35 b. There is thus, as in other embodiments, an air-flow pathway defined between the activation surface 35 b and the conduction element 36 b. An incoming air stream 43 b from a first side of the aerosol carrier 14 b is directed to a first side of the second part 35 b of the fluid-transfer article 33 b (e.g., via a gas communication pathway within the housing of the carrier). An incoming air stream 44 b from a second side of the aerosol carrier 14 b is directed to a second side of the second part 35 b of the fluid-transfer article 33 b (e.g., via a gas communication pathway within the housing of the carrier).

When the incoming air stream 43 b from the first side of the aerosol carrier 14 b reaches the first side of the second part 35 b, the incoming air stream 43 b from the first side of the aerosol carrier 14 b flows between the second part 35 b and the conduction element 36 b (or between the second part 35 b and heater 24 b in arrangements where the conduction element 36 b is absent). Likewise, when the incoming air stream 44 b from the second side of the aerosol carrier 14 b reaches the second side of the second part 35 b, the incoming air stream 44 b from the second side of the aerosol carrier 14 b flows between the second part 35 b and the conduction element 36 b (or between the second part 35 b and heater 24 b). The air streams from each side flowing are denoted by dashed lines 45 b and 44 b in FIG. 18.

As these air streams 45 b and 44 b flow, aerosol precursor on the conduction element 36 b (or on the heater 24 b) is entrained in air streams 45 b and 44 b. In use, the heater 24 b of the apparatus 12 b should raise a temperature of the conduction element 36 b to a sufficient temperature to release, or liberate, captive substances (i.e., the aerosol precursor) to form a vapor and/or aerosol, which is drawn downstream. As the air streams 45 b and 44 b continue their passages, more released aerosol precursor is entrained within the air streams 45 b and 44 b. When the air streams 45 b and 44 b entrained with aerosol precursor meet at a mouth of the outlet fluid communication pathway 48 b, they enter the outlet fluid communication pathway 48 b and continue until they pass through filter element 52 b and exit outlet fluid communication pathway 48 b, either as a single outgoing air stream, or as separate outgoing air streams 46 b (as shown). The outgoing air streams 46 b are directed to an outlet, from where it can be inhaled by the user directly (if the second end 18 b of the aerosol carrier 14 b is configured as a mouthpiece), or via a mouthpiece. The outgoing air streams 46 b entrained with aerosol precursor are directed to the outlet (e.g., via a gas communication pathway within the housing of the carrier).

Turning now to consider FIGS. 10 to 19, an alternative proposal for the apparatus of the system for aerosol delivery will now be described. It is to be appreciated that the alternative apparatus of FIGS. 10 to 19 shares several components with the apparatus described above and is intended to be used with the same general configuration of aerosol carrier 14 b described above and shown in FIG. 13 Details of the aerosol carrier 14 b will therefore not be described again in detail. Parts corresponding to those in FIGS. 10 to 18 are indicated by the same reference numerals.

In FIGS. 19 and 20, the heater 24 b is connected via a linkage 60 to a bi-metallic element 62. One end 64 of the bi-metallic element 62 is free to move, whilst the other end 66 is held by a mounting 68 which maintains a fixed relationship with the housing 32 b. The bi-metallic element 62 is mounted proximate the heater 24 b so that it receives heat from the heater 24 b when the heater 24 b is active. In this arrangement it is preferable that the linkage 60 is adapted to conduct heat from the heater 24 b to the bi-metallic element 62, so that it acts as a conduction path for heat. Additional heat will reach the bi-metallic element 62 from the heater 24 b by radiation or convection.

FIG. 19 shows the position of the heater 24 b when the heater is not activated (e.g., when the bi-metallic element 62 is at room or ambient temperature). When in this position, the conduction element 36 b is in contact with the activation surface 35 b. However, when the heater 24 b becomes activated to generate heat, that heat is transferred from the heater 24 b to the bi-metallic element 62 (possibly via the linkage 60, if provided) and the bi-metallic element 62 deforms to the position shown in FIG. 20 (deforming occurred downwardly in the drawing). Since the mounting 68 is fixed with respect to the housing 32 b and thus is 20 also fixed with respect to the fluid-transfer article 33 b, the end 64 of the bi-metallic element 62 moves away from the fluid-transfer article 33 b, thereby moving the heater 24 b, and hence moving the conduction element 36 b away from the activation surface 35 b.

FIGS. 19 and 20 also illustrate an opening 38 b in the housing 32 b, which opening 38 b is in communication with the air-intake apertures 20 b. A further opening 39 b communicates with a duct 40 b within the housing 32 b, which duct 40 b communicates with the second end 18 b.

There is thus a fluid-flow path for air (hereinafter referred to as an air-flow pathway) between openings 38 b and 39 b, linking the apertures 20 b and the second end 18 b of the aerosol carrier. In the arrangement shown in FIG. 19, that air-flow pathway is blocked by the conduction element 36 b, due to its contact with the activation surface 35 b. However, when the heater 24 b is activated, and deflection of the bi-metallic element 62 causes it to move from the position shown in FIG. 14 to the position shown in FIG. 20, the conduction element 36 b is moved away from the activation surface 35 b, thereby unblocking the air-flow pathway between openings 38 b and 39 b. Then, when the user sucks or inhales, air is drawn along the air-flow pathway.

As the conduction element 36 b moves away from the activation surface 35 b, one or more droplets of the aerosol precursor will be deposited on the conduction element 36 b and will be heated, to release vapor or a mixture of aerosol and vapor from the conduction element 36 b into the air flowing in the air-flow pathway between the openings 38 b, 39 b. The vapor or mixture passes, as the user sucks and inhales, to the second end 18 b. The configuration of the second region 35 b may be chosen so as to deposit a specific amount of liquid on the conduction element 36 b each time the conduction element 36 b moves from the position shown in FIG. 19 to the position shown in FIG. 20, to ensure consistent amounts of vapor and/or a mixture of vapor and aerosol getting into the airflow.

Once the user desists to inhale or suck, and the heater 24 b cools, the bi-metallic element 62 will revert back to its substantially straight configuration illustrated in FIG. 19 such that the heater will return to the position shown in FIG. 19 from the position shown in FIG. 20 Hence, the conduction element 36 b is brought back into contact with the activation surface 35 b when there is no air flow, and the conduction element 36 b will at least partially obstruct the end of the fluid-transfer article 33 b, reducing or preventing leakage of fluid from the fluid-transfer article 33 b when the aerosol delivery system is not being actively used by the user.

As noted above, the conduction element 36 b may be absent in some arrangements.

The conduction element 36 b, if present, may comprise a thin film of thermally conductive material, such as, for example, a metal foil (for example, aluminum, brass, copper, gold, steel, silver, or an alloy comprising anyone of the foregoing together with thermally conductive plastics and/or ceramics). In the illustrative examples of FIGS. 19 and 20, the first region 34 b of the fluid-transfer article 33 b is located at an “upstream” end of the fluid-transfer article 33 b and the second region 35 b is located at a downstream” end of the fluid-transfer article 33 b. That is, aerosol precursor is wicked, or is drawn, from the “upstream” end of the fluid-transfer article 33 b to the “downstream” end of the fluid-transfer article 33 b (as denoted by arrow B in FIG. 19). As mentioned above, the conduction element 36 b is optional. FIGS. 21 and 22 illustrate such an arrangement without such an element. Parts corresponding to those in FIGS. 19 and 20 are indicated by the same reference numerals. Thus, FIGS. 21 and 22 illustrate an arrangement in which the heater 24 b is a single element, extending from the linkage 60, and is moved due to the action of the bi-metallic element 62 from the position shown in FIG. 21 in which its upper surface is in contact with the activation surface 35 b, to the position shown in FIG. 22 in which the air-flow pathway between the openings 38 b and 39 b is unblocked, and passes over the upper surface of the heater 24 b.

In the arrangements of FIGS. 19 to 22, the bi-metallic element 62 is held via separate mounting 68 b. FIGS. 23 and 24 illustrate an embodiment in which the bi-metallic element 62 is held by the housing 32 b itself. Again, parts corresponding to those in FIGS. 19 to 22 are indicated by the same reference numerals. Thus, in the embodiment of FIGS. 23 and 24, the bi-metallic element 72 has its ends 74 and 76 in contact with the housing 32 b to be held thereby. Again, there is a linkage 70 connecting the bi-metallic element 72 to the heater 24 b. In this case, the linkage 70 is at a central region of the bi-metallic element 72. Moreover, in this embodiment the heater 24 b includes the conduction element 36 b. Again, this is optional. When the heater 24 b is activated, the bi-metallic element deforms. Since its ends 74 and 76 are fixed to the housing 32 b, its central part moves, moving the linkage 70 and hence the heater 24 b. Hence, the heater 24 b moves from the position shown in FIG. 23 in which the conduction element 36 b is in contact with the activation surface 35 b to the position shown in FIG. 24 in which the conduction element 36 b is spaced from the activation surface 35 b, and air may flow in the air-flow pathway between the openings 38 b and 39 b.

All of the embodiments of FIGS. 19 to 24 make use of a bi-metallic element to move the heater 24 b. FIGS. 25 and 26 illustrate an alternative arrangement, in which there is a drive element 80 connected via a linkage 82 to the heater 24 b. A heat sensor 84 is also in contact with the heater 24 b. When that sensor 84 detects that the heater 24 b is activated and heated, it sends a signal to the drive element 80 which activates the drive element 80 to move the linkage 82 away from the fluid-transfer article 33 b. Thus, when the sensor 84 detects that the heater 24 b is activated, the drive element 80 moves the linkage 82 which moves the heater 24 b away from the fluid-transfer article. When no heat is detected by the sensor 84 the apparatus is in the position shown in FIG. 25, in which the conduction element 36 b of the heater 24 b is in contact with the activation surface 35 b. When the heater 24 b is active, the drive element 80 causes it to adopt the position shown in FIG. 26, in which the conduction element 36 b is spaced from the activation surface 35 b, allowing air to pass along the air-flow pathway between the openings 38 b and 39 b. This embodiment is otherwise the same as the embodiments of FIGS. 19 to 24. Again, the conduction element 36 b is optional.

In the arrangements shown in FIGS. 19 to 26, the openings 38 b, 39 b are on opposite sides of the housing 32 b. FIGS. 27 and 28 show an alternative configuration, in which the fluid-transfer article 33 b is annular, and the second part 35 b is then in the form of annular diaphragm. In FIGS. 27 and 28, the heater 24 b is illustrated in a position corresponding to that shown in FIG. 20, where it is spaced from the activation surface 35 b. This enables the air flow in the apparatus to be illustrated. However, as in the arrangements of FIGS. 19 to 26, when the heater 24 b is not activated, it takes up a position in which the conduction element 36 b is in contact with the activation surface 35 b, that contact being itself annular. For simplicity, the arrangements for moving the heater 24 b are not shown in FIGS. 27 and 28. In the arrangements of FIGS. 19 to 26, or indeed other arrangements, may be usual. Thus, FIGS. 27 and 28 illustrate an aerosol carrier 14 b according to one or more possible arrangements in more detail. FIG. 27 is a cross-section side view illustration of the aerosol carrier 14 b and FIG. 28 is a perspective cross-section side view illustration of the aerosol carrier 14 b.

As can be seen from FIGS. 27 and 28, the aerosol carrier 14 b is generally tubular in form. The aerosol carrier 14 b comprises housing 32 b, which defines the external walls of the aerosol carrier 14 b and which defines therein a chamber in which are disposed the fluid-transfer article 33 b (adjacent the first end 16 b of the aerosol carrier 14 b) and internal walls defining the fluid communication pathway 48 b. Fluid communication pathway 48 b defines a fluid pathway for an outgoing air stream from the ducts 40 b to the second end 18 b of the aerosol carrier 14 b. In the examples illustrated in FIGS. 27 and 28, the fluid-transfer article 33 b is an annular shaped element located around the fluid communication pathway 48 b. In walls of the housing 32 b, there are provided inlet apertures 50 b to provide a fluid communication pathway for an incoming air stream to reach the fluid-transfer article 33 b, and particularly the one or more ducts 40 b defined between the activation surface of the fluid-transfer article 33 b and the conduction element 36 b (or between the activation surface and the 15 heater).

In the illustrated example of FIGS. 27 and 28, the aerosol carrier 14 b further comprises a filter element 52 b. The filter element 52 b is located across the fluid communication pathway 48 b such that an outgoing air stream passing through the fluid communication pathway 48 b passes through the filter element 52 b.

With reference to FIG. 28, when the heater 24 b is active and a user sucks on a mouthpiece of the apparatus (or on the second end 18 b of the aerosol carrier 14 b, if configured as a mouthpiece), air is drawn into the carrier through inlet apertures 50 b extending through walls in the housing 32 b of the aerosol carrier 14 b. As in the embodiments of FIGS. 19 to 26 the heating of the heater 24 b causes the heater 24 b to move to a position in which the activation surface 35 b is separated from the conduction element 36 b and an air-flow pathway, passing between the conduction element 36 b and the activation surface is open. An incoming air stream 43 b from a first side of the aerosol carrier 14 b is directed to a first side of the second part 35 b of the fluid-transfer article 33 b (e.g., via a gas communication pathway within the housing of the carrier). An incoming air stream 44 b from a second side of the aerosol carrier 14 b is directed to a second side of the second part 35 b of the fluid-transfer article 33 b (e.g., via a gas communication pathway within the housing of the carrier). When the incoming air stream 43 b from the first side of the aerosol carrier 14 b reaches the first side of the second part 35 b, the incoming air stream 43 b from the first side of the aerosol carrier 14 b flows between the second part 35 b and the conduction element 36 b (or between the second part 35 b and heater 24 b). Likewise, when the incoming air stream 44 b from the second side of the aerosol carrier 14 b reaches the second side of the second part 35 b, the incoming air stream 44 b from the second side of the aerosol carrier 14 b flows between the second part 35 b and the conduction element 36 b (or between the second part 35 b and heater 24 b). The air streams from each side are denoted by dashed lines 45 b and 44 b in FIG. 28 As these air streams 45 b and 44 b flow, aerosol precursor on the conduction element 36 b (or on the heater 24 b) is entrained in air streams 45 b and 44 b. In use, the heater 24 b of the apparatus 12 b to raise a temperature of the conduction element 36 b to a sufficient temperature to release, or liberate, captive substances (i.e., the aerosol precursor) to form a vapor and/or aerosol, which is drawn downstream. As the air streams 45 b and 44 b continue their passages, more released aerosol precursor is entrained within the air streams 45 b and 44 b. When the air streams 45 b and 44 b entrained with aerosol precursor meet at a mouth of the outlet fluid communication pathway 48 b, they enter the outlet fluid communication pathway 48 b and continue until they pass through filter element 52 b and exit outlet fluid communication pathway 48 b, either as a single outgoing air stream, or as separate outgoing air streams 46 b (as shown). The outgoing air streams 46 b are directed to an outlet, from where it can be inhaled by the user directly (if the second end 18 b of the aerosol carrier 14 b is configured as a mouthpiece), or via a mouthpiece. The outgoing air streams 46 b entrained with aerosol precursor are directed to the outlet (e.g., via a gas communication pathway within the housing of the carrier).

Turning now to consider FIGS. 20 to 27, another alternative proposal for the apparatus of the system for 35 aerosol delivery will now be described. It is to be appreciated that the alternative apparatus of FIGS. 20 to 27 shares several components with the apparatuses described above and is intended to be used with the same general configuration of aerosol carrier 14 b described above and shown in FIG. 13. Details of the aerosol carrier 14 b will therefore not be described again in detail. Parts corresponding to those in FIGS. 10 to 28 are indicated by the same reference numerals.

In FIGS. 29 and 30, the heater 24 b is mounted on a resilient element 90. That resilient element 90 may be, e.g., a spring such as a coil spring, or may be a resilient block. The resilient element 90 biases the heater 24 b towards the position shown in FIG. 29, in which the conduction element 36 b is in contact with the activation surface 35 b.

FIGS. 29 and 30 also illustrate an opening 38 b in the housing 32 b, which opening 38 b is in communication with the air-intake apertures 20 b. A further opening 39 b communicates with a duct 40 b within the housing 32 b, which duct 40 b communicates with the second end 18 b. There is thus a fluid-flow path for air (hereinafter referred to as an air-flow pathway) between openings 38 b and 39 b, linking the apertures 20 b and the second end 18 b of the aerosol carrier. In the arrangement shown in FIG. 29, that air-flow pathway is blocked by the conduction element 36 b, due to its contact with the activation surface 35 b.

However, when the user inhales or sucks, air is caused to move between the openings 38 b and 39 b, causing an air pressure which acts against the biasing means to move the conduction element 36 b, and hence the rest of the heater, away from the activation surface 35 b. The heater 24 b thus moves to the position shown in FIG. 30, against the biasing force of the biasing element 90, in which the air-flow pathway between the openings 38 b and 39 b is unblocked. Thus, air can be drawn along the air-flow pathway through the duct 40 b to the user. As can be appreciated, the biasing of the heater 24 b into the position shown in FIG. 29 needs to be sufficiently strong to hold it in that position, but not so strong that it will prevent air flow moving the heater to the position shown in FIG. 30.

As the conduction element 36 b moves away from the activation surface 35 b, one or more droplets of the aerosol precursor will be deposited on the conduction element 36 b and heated, to release vapor or a mixture of aerosol and vapor from the conduction element 36 b into the air flowing in the air-flow pathway between the openings 38 b, 39 b. The vapor or mixture passes, as the user sucks and inhales, to the second end 18 b. The configuration of the second region 35 b may be chosen so as to deposit a specific amount of liquid on the conduction element 36 b each time the conduction element 36 b moves from the position shown in FIG. 29 to the position shown in FIG. 30, to ensure consistent amounts of vapor and/or a mixture of vapor and aerosol getting into the airflow. Once the user desists to inhale or suck, the flow of air between openings 38 b and 39 b will stop and the heater will return to the position shown in FIG. 29 from the position shown in FIG. 30 under the biasing influence of the biasing element 90. Hence, the activation surface 35 b moves back in to contact with the conduction element 36 b when there is no air flow, and the conduction element 36 b will at least partially obstruct the end of the fluid-transfer article 33 b, reducing or preventing leakage of fluid from the fluid-transfer article 33 b when the aerosol delivery system is not being actively used by the user.

As noted above, the conduction element 36 b may be absent in some arrangements. The conduction element 36 b, if present, may comprise a thin film of thermally conductive material, such as, for example, a metal foil (for example, aluminum, brass, copper, gold, steel, silver, or an alloy comprising anyone of the foregoing together with thermally conductive plastics and/or ceramics).

In the illustrative examples of FIGS. 29 and 30, the first region 34 b of the fluid-transfer article 33 b is located at an “upstream” end of the fluid-transfer article 33 b and the second region 35 b is located at a downstream” end of the fluid-transfer article 33 b. That is, aerosol precursor is wicked, or is drawn, from the “upstream” end of the fluid-transfer article 33 b to the “downstream” end of the fluid-transfer article 33 b (as denoted by arrow B in FIG. 29).

As mentioned above, the conduction element 36 b is optional. FIGS. 31 and 32 illustrate an arrangement in which the conduction element 36 b is omitted. Parts corresponding to those of the arrangement illustrated in FIGS. 29 and 30 are indicated by the same reference numerals. Thus, FIGS. 31 and 32 illustrate an arrangement in which the heater 24 b is a single element, extending from the resilient element 90, and which is moved due to air flow along the air-flow pathway from the position shown in FIG. 31 in which its upper surface is in contact with the activation surface 35 b, to the position shown in FIG. 32 in which the air-flow pathway between the openings 38 b and 39 b is unblocked, and passes over the upper surface of the heater 24 b.

In the arrangement of FIGS. 29 to 32, the heater 24 b is mounted on a resilient element 90, which biases the heater 24 b in an upwards direction (in the orientation illustrated) so that its upper surface (which may be formed by the conduction element 36 b) is in contact with the activation surface 35 b. FIGS. 33 and 34 illustrate an arrangement in which the heater 24 b is mounted on a hinged element 92 which pivots about a hinge 94. FIG. 33 illustrates a configuration in which the hinged element 92 holds the conduction element 36 b of the heater 24 b in contact with the activation surface 35 b. This corresponds to, e.g., the arrangement shown in FIG. 29 When the user sucks or inhales, the flow of air causes the heater 24 b to move hingedly to open the air-flow pathway between the openings 38 b and 39 b. The element 92 hinges on the hinge 94 to a position shown in FIG. 34 in which air can flow between the openings 38 b and 39 b. In the arrangements shown in FIGS. 29 to 34, the openings 38 b, 39 b are on opposite sides of the housing 32 b. FIGS. 35 and 36 show an alternative configuration, in which the fluid-transfer article is annular, and the second part 35 b is then in the form of an annular diaphragm. In FIGS. 35 and 36, the heater 24 b is illustrated in a position corresponding to that shown in FIG. 30, where it is spaced from the activation surface 35 b. This enables the air flow in the apparatus to be illustrated. However, as in the arrangements of FIGS. 29 to 34, when the heater 24 b is not activated it takes up a position in which the conduction element 36 b is in contact with the activation surface 35 b, the contact being itself annular. FIGS. 35 and 36 show an arrangement in which the heater 24 b is mounted on a resilient element 90, as in the arrangements of FIGS. 29 to 32. However, hinged arrangements such as illustrated in FIGS. 33 and 34 may also be possible. Thus, FIGS. 35 and 36 illustrate an aerosol carrier 14 b according to one or more possible arrangements in more detail. FIG. 35 is a cross-section side view illustration of the aerosol carrier 14 b and FIG. 36 is a perspective cross-section side view illustration of the aerosol carrier 14 b.

As can be seen from FIGS. 35 and 36, the aerosol carrier 14 b is generally tubular in form. The aerosol carrier 14 b comprises housing 32 b, which defines the external walls of the aerosol carrier 14 b and which defines therein a chamber in which are disposed the fluid-transfer article 33 b (adjacent the first end 16 b of the aerosol carrier 14 b) and internal walls defining the fluid communication pathway 48 b. Fluid communication pathway 48 b defines a fluid pathway for an outgoing air stream from the ducts 40 b to the second end 18 b of the aerosol carrier 14 b. In the example illustrated in FIGS. 35 and 36, the fluid-transfer article 33 b is an annular shaped element located around the fluid communication pathway 48 b.

In walls of the housing 32 b, there are provided inlet apertures 50 b to provide a fluid communication pathway for an incoming air stream to reach the fluid-transfer article 33 b, and particularly the one or more ducts 40 b defined between the activation surface of the fluid-transfer article 33 b and the conduction element 36 b (or between the activation surface and the 15 heater).

In the illustrated example of FIGS. 35 and 36, the aerosol carrier 14 b further comprises a filter element 52 b. The filter element 52 b is located across the fluid communication pathway 48 b such that an outgoing air stream passing through the fluid communication pathway 48 b passes through the filter element 52 b. With reference to FIG. 36, when a user sucks on a mouthpiece of the apparatus (or on the second end 18 b of the aerosol carrier 14 b, if configured as a mouthpiece), air is drawn into the carrier through inlet apertures 50 b extending through walls in the housing 32 b of the aerosol carrier 14 b. As in the embodiments of FIGS. 29 to 34 this causes the heater 24 b to move to a position in which the activation surface 35 b is separated from the conduction element 36 b and an air-flow pathway, passing between the conduction element 36 b and the activation surface is open.

An incoming air stream 43 b from a first side of the aerosol carrier 14 b is directed to a first side of the second part 35 b of the fluid-transfer article 33 b (e.g., via a gas communication pathway within the housing of the carrier). An incoming air stream 44 b from a second side of the aerosol carrier 14 b is directed to a second side of the second part 35 b of the fluid-transfer article 33 b (e.g., via a gas communication pathway within the housing of the carrier). When the incoming air stream 43 b from the first side of the aerosol carrier 14 b reaches the first side of the second part 35 b, the incoming air stream 43 b from the first side of the aerosol carrier 14 b flows between the second part 35 b and the conduction element 36 b (or between the second part 35 b and heater 24 b). Likewise, when the incoming air stream 44 b from the second side of the aerosol carrier 14 b reaches the second side of the second part 35 b, the incoming air stream 44 b from the second side of the aerosol carrier 14 b flows between the second part 35 b and the conduction element 36 b (or between the second part 35 b and heater 24 b). The air streams from each side are denoted by dashed lines 45 b and 44 b in FIG. 36 As these air streams 45 b and 44 b flow, aerosol precursor on the conduction element 36 b (or on the heater 24 b) is entrained in air streams 45 b and 44 b. In use, the heater 24 b of the apparatus 12 b to raise a temperature of the conduction element 36 b to a sufficient temperature to release, or liberate, captive substances (i.e., the aerosol precursor) to form a vapor and/or aerosol, which is drawn downstream. As the air streams 45 b and 44 b continue their passages, more released aerosol precursor is entrained within the air streams 45 b and 44 b. When the air streams 45 b and 44 b entrained with aerosol precursor meet at a mouth of the outlet fluid communication pathway 48 b, they enter the outlet fluid communication pathway 48 b and continue until they pass through filter element 52 b and exit outlet fluid communication pathway 48 b, either as a single outgoing air stream, or as separate outgoing air streams 46 b (as shown). The outgoing air streams 46 b are directed to an outlet, from where it can be inhaled by the user directly (if the second end 18 b of the aerosol carrier 14 b is configured as a mouthpiece), or via a mouthpiece. The outgoing air streams 46 b entrained with aerosol precursor are directed to the outlet (e.g., via a gas communication pathway within the housing of the carrier).

FIG. 37 is an exploded perspective view illustration of a kit-of-parts for assembling an aerosol delivery system 10 b.

In any of the embodiments of the second mode described above the second part 35 b of the fluid-transfer article may have a thickness of less than 5 mm. In other embodiments it may have a thickness of: less than 3.5 mm, less than 3 mm, less than 2.5 mm, less than 2 mm, less than 1.9 mm, less than 1.8 mm, less than 1.7 mm, less than 1.6 mm, less than 1.5 mm, less than 1.4 mm, less than 1.3 mm, less than 1.2 mm, less than 1.1 mm, less than 1 mm, less than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less than 0.6 mm, less than 0.5 mm, less than 0.4 mm, less than 0.3 mm, less than 0.2 mm, or less than 0.1 mm. As will be appreciated, in the arrangements described above, the fluid-transfer article 33 b is provided within a housing 32 b of the aerosol carrier 14 b. In such arrangements, the housing of the aerosol carrier 14 b serves to protect the aerosol precursor-containing fluid-transfer article 33 b, whilst also allowing the aerosol carrier 14 b to be handled by a user without his/her fingers coming into contact with the aerosol precursor liquid retained therein. In such arrangements, it will be appreciated that the carrier 14 has a multi-part construction.

Third Mode: A fluid-transfer article for holding an aerosol precursor including a hole and a heater adjacent to the hole which is deformable in response to temperature change.

Aspects and embodiments of the third mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

In general outline, one or more embodiments of the third mode in accordance with the present disclosure may provide a system for aerosol delivery in which an aerosol carrier may be inserted into a receptacle (e.g., a “heating chamber”) of an apparatus for initiating and maintaining release of an aerosol from the aerosol carrier. Another end, or another end portion, of the aerosol carrier may protrude from the apparatus and can be inserted into the mouth of a user for the inhalation of aerosol released from the aerosol carrier cartridge during operation of the apparatus.

Hereinafter, and for convenience only, “system for aerosol delivery” shall be referred to as “aerosol delivery system”.

Referring now to FIG. 38, there is illustrated a perspective view of an aerosol delivery system 10 c comprising an aerosol generation apparatus 12 c operative to initiate and maintain release of aerosol from a fluid-transfer article in an aerosol carrier 14 c. In the arrangement of FIG. 38, the aerosol carrier 14 c is shown with a first end 16 c thereof and a portion of the length of the aerosol carrier 14 c located within a receptacle of the apparatus 12 c. A remaining portion of the aerosol carrier 14 c extends out of the receptacle. This remaining portion of the aerosol carrier 14 c, terminating at a second end 18 c of the aerosol carrier, is configured for insertion into a user's mouth. A vapor and/or aerosol is produced when a heater (not shown in FIG. 38) of the apparatus 12 c heats a fluid-transfer article in the aerosol carrier 14 c to release a vapor and/or an aerosol, and this can be delivered to the user, when the user sucks or inhales, via a fluid passage in communication with an outlet of the aerosol carrier 14 c from the fluid-transfer article to the second end 18 c.

The apparatus 12 c also comprises air-intake apertures 20 c in the housing of the apparatus 12 c to provide a passage for air to be drawn into the interior of the apparatus 12 c (when the user sucks or inhales) for delivery to the first end 16 c of the aerosol carrier 14 c, so that the air can be drawn across an activation surface of a fluid-transfer article located within a housing of the aerosol carrier 14 c during use. Optionally, these apertures may be perforations in the housing of the apparatus 12 c.

A fluid-transfer article (not shown in FIG. 38, but described hereinafter with reference to FIGS. 42, 43, 44, 45, and 46) is located within a housing of the aerosol carrier 14 c. The fluid-transfer article contains an aerosol precursor material, which may include at least one of: nicotine; a nicotine precursor material; a nicotine compound; and one or more flavorings. The fluid-transfer article is located within the housing of the aerosol carrier 14 c to allow air drawn into the aerosol carrier 14 c at, or proximal, the first end 16 c to flow across an activation surface of the fluid-transfer article. As air passes across the activation surface of the fluid-transfer article, an aerosol may be entrained in the air stream from a substrate forming the fluid-transfer article, e.g., via diffusion from the substrate to the air stream and/or via vaporization of the aerosol precursor material and release from the fluid-transfer article under heating.

The substrate forming the article 31 c comprises a porous material where pores of the porous material hold, contain, carry, or bear the aerosol precursor material. In particular, the porous material of the fluid-transfer article may be a polymeric wicking material such as, for example, a sintered material. Particular examples of material suitable for the fluid-transfer article include: Polyetherimide (PEI); Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK); Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular Weight Polyethylene. Other suitable materials may comprise, for example, BioVyon™ (by Porvair Filtration Group Ltd) and materials available from Porex®. Further optionally, a substrate forming the fluid-transfer article may comprise Polypropylene (PP) or Polyethylene Terephthalate (PET). All such materials may be described as heat resistant polymeric wicking material in the context of the third mode of the present disclosure. The aerosol carrier 14 c is removable from the apparatus 12 c so that it may be disposed of when expired. After removal of a used aerosol carrier 14 c, a replacement aerosol carrier 14 c can be inserted into the apparatus 12 c to replace the used aerosol carrier 14 c.

FIG. 39 is a cross-sectional side view illustration of a part of apparatus 12 c of the aerosol delivery system 10 c. The apparatus 12 c comprises a receptacle 22 c in which is located a portion of the aerosol carrier 14 c. In one or more optional arrangements, the receptacle 22 c may enclose the aerosol carrier 14 c. The apparatus 12 c also comprise a heater 24 c, which opposes an activation surface of the fluid-transfer article (not shown in FIG. 39) of the aerosol carrier 14 c when an aerosol carrier 14 c is located within the receptacle 22 c. Air flows into the apparatus 12 c (in particular, into a closed end of the receptacle 22 c) via air-intake apertures 20 c. From the closed end of the receptacle 22 c, the air is drawn into the aerosol carrier 14 c (under the action of the user inhaling or sucking on the second end 18 c) and expelled at the second end 18 c. As the air flows into the aerosol carrier 14 c, it passes across the activation surface of the fluid-transfer article. Heat from the heater 24 c, which opposes the activation surface of the fluid-transfer article, causes vaporization of aerosol precursor material at the activation surface of the fluid-transfer article and an aerosol is created in the air flowing over the activation surface. Thus, through the application of heat in the region of the activation surface of the fluid-transfer article, an aerosol is released, or liberated, from the fluid-transfer article, and is drawn from the material of the aerosol carrier unit by the air flowing across the activation surface and is transported in the air flow to via outlet conduits (not shown in FIG. 39) in the housing of the aerosol carrier 14 c to the second end 18 c. The direction of air flow is illustrated by arrows in FIG. 39.

To achieve release of the captive aerosol from the fluid-transfer article, the fluid-transfer article of the aerosol carrier 14 c is heated by the heater 24 c. As a user sucks or inhales on second end 18 c of the aerosol carrier 14 c, the aerosol released from the fluid-transfer article and entrained in the air flowing across the activation surface of the fluid-transfer article is drawn through the outlet conduits (not shown) in the housing of the aerosol carrier 14 c towards the second end 18 c and onwards into the user's mouth.

Turning now to FIG. 40 a cross-sectional side view of the aerosol delivery system 10 c is schematically illustrated showing the features described above in relation to FIGS. 38 and 39 in more detail. As can be seen, apparatus 12 c comprises a housing 26 c, in which are located the receptacle 22 c and heater 24 c. The housing 26 c also contains control circuitry (not shown) operative by a user, or upon detection of air and/or vapor being drawn into the apparatus 12 c through air-intake apertures 20 c, i.e., when the user sucks or inhales. Additionally, the housing 26 c comprises an electrical energy supply 28 c, for example, a battery. Optionally, the battery comprises a rechargeable lithium-ion battery. The housing 26 c also comprises a coupling 29 c for electrically (and optionally mechanically) coupling the electrical energy supply 28 c to control circuitry (not shown) for powering and controlling operation of the heater 24 c.

Responsive to activation of the control circuitry of apparatus 12 c, the heater 24 c heats the fluid-transfer article (not shown in FIG. 40 of aerosol carrier 14 c. This heating process initiates (and, through continued operation, maintains) release of vapor and/or an aerosol from the activation surface of the fluid-transfer article. The vapor and/or aerosol formed as a result of the heating process is entrained into a stream of air being drawn across the activation surface of the fluid-transfer article (as the user sucks or inhales). The stream of air with the entrained vapor and/or aerosol passes through the aerosol carrier 14 c via outlet conduits (not shown) and exits the aerosol carrier 14 c at second end 18 c for delivery to the user. This process is briefly described above in relation to FIG. 39, where arrows schematically denote the flow of the air stream into the apparatus 12 c and through the aerosol carrier 14 c, and the flow of the air stream with the entrained vapor and/or aerosol through the aerosol carrier 14 c.

FIGS. 41 to 43 schematically illustrate the aerosol carrier 14 c in more detail (and, in FIGS. 42 and 43, features within the receptacle in more detail).

FIG. 41 illustrates the exterior of the aerosol carrier 14 c, which comprises housing 30 c for housing said fluid-transfer article (not shown) and at least one other internal component. The particular housing 30 c illustrated in FIG. 41 comprises a tubular member, which may be generally cylindrical in form, and which is configured to be received within the receptacle of the apparatus. First end 16 c of the aerosol carrier 14 c is for location to oppose the heater of the apparatus, and second end 18 c (and the region adjacent the second end 18 c) is configured for insertion into a user's mouth.

FIGS. 42 to 44 illustrate some internal components of the aerosol carrier 14 c and of the heater 24 c of apparatus 12 c.

As described above, the aerosol carrier 14 c comprises an article 31 c. Optionally, there may be a conduction element 36 c (as shown in FIG. 42) facing the fluid-transfer article, the conduction element 36 c being part of the heater 24 c. In one or more arrangements, the aerosol carrier 14 c is located within the receptacle of the apparatus such that the activation surface of the fluid-transfer article opposes the heater of the apparatus and receives heat directly from the heater of the apparatus. When aerosol carrier 14 c is located within the receptacle of the apparatus such that the activation surface of the fluid-transfer article is located to oppose the heater of the apparatus, the conduction element 36 c is disposed between the rest of the heater 24 c and the activation surface of the article 31 c. Heat may be transferred to the activation surface via conduction through conduction element 36 c (i.e., application of heat to the activation surface is indirect).

Further components not shown in FIGS. 42 to 44 comprise: an inlet conduit, via which air can be drawn into the aerosol carrier 14 c; an outlet conduit, via which an air stream entrained with aerosol can be drawn from the aerosol carrier 14 c; a filter element; and a reservoir for storing aerosol precursor material and for providing the aerosol precursor material to the article 31 c.

In FIGS. 42 to 44, the aerosol carrier is shown as comprising the article 31 c located within housing 30 c. The fluid-transfer article 31 c comprises a first region 32 c holding an aerosol precursor. In one or more arrangements, the first region 32 c of the fluid-transfer article 31 c comprises a reservoir for holding the aerosol precursor. The first region 32 c can be the sole reservoir of the aerosol carrier 14 c, or it can be arranged in fluid communication with a separate reservoir, where aerosol precursor is stored for supply to the first region 32 c. As shown in FIGS. 42 and 43, the material forming the first region 32 c comprises a porous structure, whose pore diameter size may vary between one end of the first region 32 c and another end of the first region 32 c. In the illustrated examples of FIGS. 42 and 43, the pore diameter size decreases from a first end remote from heater 24 c (the upper end is as shown in the figure) to a second end. Although the figure illustrates the pore diameter size changing in a stepwise manner (i.e., a first part with pores having a diameter of first size, and a second part with pores having a diameter of second, smaller size), the change in pore size in the first region 32 c may be gradual rather than step-wise. This configuration of pores having a decreasing diameter size can provide a wicking effect, which can serve to draw fluid through the first region 32 c, towards heater 24 c. The fluid-transfer article 31 c also comprises a second region having a first part 32 c and another part in the form of a plate 34 c. Aerosol precursor is drawn from the first region 32 c to the first part 32 c of the second region by the wicking effect of the material forming the first region 32 c. Thus, the first region 32 c is configured to transfer the aerosol precursor to the second region 33 c of the article 31 c. The first part 32 c of the second region may itself comprise a porous structure. It is then preferable that the pore diameter size of the porous structure of the first part 32 c of the second region is smaller than the pore diameter size of the immediately adjacent part of the first region 32 c.

The first region 32 c of the fluid-transfer article need not be of porous polymer material as described above. It may instead be a simple hollow reservoir filled with liquid aerosol precursor. The liquid aerosol precursor will then pass directly from the first region 32 c to the second region 33 c. Similarly, the first part 32 c of the second region, need not be of porous polymer material. Instead, it may be of any material with a “wicking” action which will transfer aerosol precursor from the first region 32 c to the activation surface 35, for example a fibrous wick. It may even be possible for both the first region 32 c and the first part 32 c of the second region to form a hollow reservoir, with that reservoir being partly bounded by the plate 34 c.

As mentioned above, the second region of the fluid-transfer article has a plate 34 c with a hole 37 c (or possibly a plurality of holes) therethrough. Aerosol precursor can pass through the hole 37 c from the first part 32 c of the second region, provided the hole 37 c is not blocked. The plate 34 c may be formed from metal, or from a plastic material.

FIG. 42 then illustrates the configuration of the device with the heater 24 c at a first temperature, such as room temperature. As shown in FIG. 42, the heater 24 c occupies a position such that a part of the conduction element 36 c of the heater 24 c is in contact with the plate 34 c so as to block the hole 37 c. There is also a gap 35 c between the heater 24 c and the coupling 29 c. The housing 30 c has an opening 38 c therein, which may receive air from the apertures 20 c, and another opening 39 c leading to a duct 40 c within the housing 30 c, which duct 40 c leads to the second downstream end 18 c of the aerosol carrier 14 c. Thus, in the position shown in FIG. 42, air can pass from the apertures 20 c though the opening 38 c into gap 35 c between the heater 24 c and the coupling 29 c, and from the gap 35 c through the opening 38 c into the duct 40 c and hence to the second end 18 c. In the configuration illustrated in FIG. 42, the aforementioned air flow is obstructed by the heater 24 c from reaching the plate 34 c, particularly that part of the plate 34 c in which the hole 37 c is formed.

In the position shown in FIG. 42, the parts of the periphery of the heater 24 c visible in the Figure are not attached to the housing 30 c and are free to move. On the other hand, the parts of the periphery of the heater 24 c perpendicular to the view of FIG. 42 are attached to the housing 30 c, or to a mechanical barrier or seating adjacent the housing 30 c, to hold those parts of the periphery of the heater 24 c in place.

When the heater 24 c is activated, it will heat up. The materials of the heater 24 c, including the conduction element 36 c, are chosen so that they expand under such heating, and so the heater 24 c, including the conduction element 36 c, will deform, as part of its periphery is held in position and part is free to move. In particular, the heater 24 c will deform from the position shown in FIG. 42 to the position shown in FIG. 43, with the view of FIG. 43 being perpendicular to the view of FIG. 42 The effect of this deformation is to create a space 42 c between the conduction element 36 c and the plate 34 c, which space 42 c is in communication with the openings 38 c and 39. Thus, space 42 c now forms part of an air-flow pathway between the openings 38 c and 39, which air-flow pathway passes between the hole 37 c and the conduction element 36 c.

FIG. 43 illustrates how, because parts of the periphery of the heater 24 c are held in place due to their attachment to the housing 30 c or by a mechanical barrier or seating, the heater 24 c adopts a domed shape perpendicular to the view in FIG. 42 FIG. 44 shows a view perpendicular to FIG. 43, and hence corresponding to FIG. 42 but with the heater 24 c at an elevated temperature, to illustrate that the space 42 c communicates with the openings 38 c and 39. Thus, the movement of the heater between the position shown in FIG. 42, and the position shown in FIGS. 43 and 44, has the effect of unblocking, or removing the obstruction from, the air-flow pathway from the opening 38 c to the opening 39 c which passes between the plate 34 c and the conduction element 36 c of the heater 24 c. In the obstructed position of FIG. 42, the heater 24 c blocks or occludes the hole 37 c and prevents aerosol precursor reaching any air flowing between the openings 38 c and 39, whereas in the position shown in FIGS. 43 and 44, the hole 37 c opened and is exposed to air flowing between the openings 38 c and 39.

When the device is not being used, and the heater 24 c in in the position shown in FIG. 42, aerosol precursor will pass through the hole 37 c, and will be deposited on the conduction element 36 c of the heater 24 c. When the device is in use, and the heater heats up, such aerosol precursor on the conduction element 36 c, will be heated by the heat generated by the heater 24 c, and vaporized in the space 42 c. That vapor, or a mixture of aerosol and vapor, will then mix with air flowing between the openings 38 c and 39 through the space 42 c as the user draws on the mouthpiece at end 18 c, and air and the vapor or mixture of vapor and aerosol will pass through the opening 39 c, and through the duct 40 c, to the end 18 c, and hence to the user.

Thus, droplets of aerosol precursor will be transferred from the second part 33 c of the second region through the hole 37 c to the conduction element 36 c, and move away from the plate 34 c as the heater 24 c changes from the position shown in FIG. 42 to the position shown in FIGS. 43 and 44. Those droplets of aerosol precursor will then be wholly or partially vaporized by the elevated temperature of the conduction element 36 c, with any additional aerosol precursor passing through the hole 37 c into the space 42 c also being vaporized. In practice, aerosol precursor may “pool” in the space 42 c, until it is vaporized, although the amount of aerosol precursor which is on the conduction element 36 c or in the space 42 c is preferably determined so that substantially all of it will be vaporized when the heater 24 c is active.

The configurations of the second part 33 c of the second region, the plate 34 c and the hole 37 c may be chosen so as to deposit a specific amount of liquid on the conduction element 36 c each time the conduction element 36 c moves from the position shown in FIG. 42 to the positions shown in FIGS. 43 and 44, to ensure consistent amounts of vapor and/or a mixture of vapor and aerosol getting into the airflow. There may be a single hole 37 c, or a plurality of holes, through the plate 34 c. In the latter case, the movement of the heater 24 c (particularly the conduction element 36 c) needs to be sufficient to block all, or at least most of, the holes when the heater 24 c is not active.

Once the user desists to inhale or suck, the air flow will stop. The heater may be allowed to cool in this state, to return to the position shown in FIG. 42 from the position shown in FIG. 43 so that there is a cyclic operation with the air-flow pathway between the plate 34 c and the conduction element 36 c being closed or opened (obstructed or un-obstructed) through a cycle of inhalations by the user. Alternatively, the heater 24 c may remain heated between inhalations by the user, with the space 41 c being filled with vaporized aerosol precursor between inhalations.

The materials of the heater 24 c, including the conduction element 36 c, are preferably chosen such that their thermal expansion is consistent, allowing there to be a known relationship between the temperature of the heater 24 c and the distance over which the central part of the heater 24 c moves away from the plate 34 c. In this way, the distance between the plate 34 c and the conduction element 36 c, and hence the size of the air-flow pathway between the plate 34 c and the conduction element 36 c, can be chosen to achieve a satisfactory volumetric flow rate when the user inhales. Attachment of parts of the periphery of the heater 24 c to the housing 30 c, and the non-attachment of other parts of the periphery, allows the heater to “dome” as illustrated in FIG. 43, to open or un-obstruct the air-flow pathway between the plate 34 c and the conduction element 36 c.

As noted above, the conduction element 36 c may be absent in some arrangements, in which case the plate 34 c and the second part 33 c will receive heat directly from the heater 24 c. Also, in the arrangements of FIGS. 42 to 44, the whole of the heater 24 c deforms as the temperature changes. It may be possible to have an arrangement in which only part of the heater, such as the conduction element 36 c, deforms as the temperature changes. In general, it is the heating surface of the heater which must deform to allow air to reach the space 42 c between the plate 34 c and the heater 24 c.

The conduction element 36 c, if present, may comprise a thin film of thermally conductive material, such as, for example, a metal foil (for example, aluminum, brass, copper, gold, steel, silver, or an alloy comprising anyone of the foregoing together with thermally conductive plastics and/or ceramics).

In the illustrative examples of FIGS. 42 and 43, the first region 32 c of the article 31 c is located at an “upstream” end of the article 31 c, the first part 32 c of the second region is located towards a downstream” end of the article 31 c relative to the first region 32 c, and the plate 34 c is at the “downstream” end. That is, aerosol precursor is wicked, or is drawn, from the “upstream” end of the article 31 c to the “downstream” end of the article 31 c (as denoted by arrow C in FIG. 42).

In the arrangements shown in FIGS. 42 to 44, the air flow apertures 38 c, 39 c are on opposite sides of the housing 30 c. FIGS. 45 and 46 show an alternative configuration, in which the fluid-transfer article is annular. In FIGS. 45 and 46, the conduction element 36 c is illustrated in a position corresponding to that shown in FIGS. 43 and 44, where it is spaced from the plate 34 c. This enables the air flow in the apparatus to be illustrated. However, as in the arrangement of FIGS. 42 to 44, when the heater is cool, the conduction element 36 c is deformed and is in contact with the plate 34 c. The deformation of the heater 24 c may have to be slightly greater than in the arrangement shown in FIG. 42, to ensure that the conduction element 36 c makes sufficient contact with the plate 34 c, which itself is annular due to the annular configuration. The operation of the embodiment of FIGS. 45 and 46 is otherwise similar to that of the embodiments of FIGS. 42 to 44. The hole 37 c in the plate 34 c may be a single annular opening, or a plurality of holes may be formed in an annular arrangement around the plate 34 c.

Thus, FIGS. 45 and 46 illustrate an aerosol carrier 14 c according to one or more possible arrangements in more detail. FIG. 45 is a cross-section side view illustration of the aerosol carrier 14 c and FIG. 46 is a perspective cross-section side view illustration of the aerosol carrier 14 c.

As can be seen from FIGS. 45 and 46, the aerosol carrier 14 c is generally tubular in form. The aerosol carrier 14 c comprises housing 30 c, which defines the external walls of the aerosol carrier 14 c and which defines therein a chamber in which are disposed the article 31 c (adjacent the first end 16 c of the aerosol carrier 14 c) and internal walls defining the fluid communication pathway 48 c. Fluid communication pathway 48 c defines a fluid pathway for an outgoing air stream from the channels 40 c to the second end 18 c of the aerosol carrier 14 c. In the examples illustrated in FIGS. 45 and 46, the article 31 c is an annular shaped element located around the fluid communication pathway 48 c. In walls of the housing 30 c, there are provided inlet apertures 50 c to provide a fluid communication pathway for an incoming air stream to reach the article 31 c, and particularly the one or more channels 40 c defined between the activation surface of the article 31 c and the conduction element 36 c (or between the activation surface and the heater). In the illustrated example of FIGS. 45 and 46, the aerosol carrier 14 c further comprises a filter element 52 c. The filter element 52 c is located across the fluid communication pathway 48 c such that an outgoing air stream passing through the fluid communication pathway 48 c passes through the filter element 52 c.

With reference to FIG. 45, when the heater is activated and a user sucks on a mouthpiece of the apparatus (or on the second end 18 c of the aerosol carrier 14 c, if configured as a mouthpiece), air is drawn into the carrier through inlet apertures 50 c extending through walls in the housing 30 c of the aerosol carrier 14 c. On activation of the heater, the heater 24 c (and particularly the conduction element 36 c) will deform to move the conduction element 36 c clear of the plate 34 c, thereby to unblock the hole or holes 37 c. There is then, as in other embodiments, an air-flow pathway between the plate 34 c and the conduction element 36 c. An incoming air stream 43 c from a first side of the aerosol carrier 14 c is directed to a first side of the plate 34 c of the article 31 c (e.g., via a gas communication pathway within the housing of the carrier). When the incoming air stream 44 c from a second side of the aerosol carrier 14 c is directed to a second side of the second part 33 c of the article 31 c (e.g., via a gas communication pathway within the housing of the carrier). When the incoming air stream 43 c from the first side of the aerosol carrier 14 c reaches the first side of the plate 34 c, the incoming air stream 43 c from the first side of the aerosol carrier 14 c flows between the plate 34 c and the conduction element 36 c (or between the plate 34 c and heater 24 c). Likewise, when the incoming air stream 44 c from the second side of the aerosol carrier 14 c reaches the second side of the plate 34 c, the incoming air stream 44 c from the second side of the aerosol carrier 14 c flows between the second part 32 c and the conduction element 36 c (or between the plate 34 c and heater 24 c). The air streams from each side flowing are denoted by dashed lines 45 c and 44 b in FIG. 46 As these air streams 45 c and 44 b flow, aerosol precursor on the conduction element 36 c (or on the heater 24 c) is entrained in air streams 45 c and 44 b.

In use, the heater 24 c of the apparatus 12 c should raise a temperature of the conduction element 36 c to a sufficient temperature to release, or liberate, captive substances (i.e., the aerosol precursor) to form a vapor and/or aerosol, which is drawn downstream. As the air streams 45 c and 44 b continue their passages, more released aerosol precursor is entrained within the air streams 45 c and 44 b. When the air streams 45 c and 44 b entrained with aerosol precursor meet at a mouth of the fluid communication pathway 48 c, they enter the fluid communication pathway 48 c and continue until they pass through filter element 52 c and fluid communication pathway 48 c, either as a single outgoing air stream, or as separate outgoing air streams 47 c (as shown). The outgoing air streams 47 c are directed to an outlet, from where it can be inhaled by the user directly (if the second end 18 c of the aerosol carrier 14 c is configured as a mouthpiece), or via a mouthpiece. The outgoing air streams 47 c entrained with aerosol precursor are directed to the outlet (e.g., via a gas communication pathway within the housing of the carrier). FIG. 47 is an exploded perspective view illustration of a kit-of-parts for assembling an aerosol delivery system 10 c.

In any of the embodiments described above the plate 34 c may have a thickness of less than 5 mm. In other embodiments it may have a thickness of: less than 3.5 mm, less than 3 mm, less than 2.5 mm, less than 2 mm, less than 1.9 mm, less than 1.8 mm, less than 1.7 mm, less than 1.6 mm, less than 1.5 mm, less than 1.4 mm, less than 1.3 mm, less than 1.2 mm, less than 1.1 mm, less than 1 mm, less than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less than 0.6 mm, less than 0.5 mm, less than 0.4 mm, less than 0.3 mm, less than 0.2 mm, or less than 0.1 mm. As will be appreciated, in the arrangements described above, the article 31 c is provided within a housing 30 c of the aerosol carrier 14 c. In such arrangements, the housing of the carrier 14 c serves to protect the aerosol precursor-containing fluid-transfer article 31 c, whilst also allowing the carrier 14 c to be handled by a user without his/her fingers coming into contact with the aerosol precursor liquid retained therein. In such arrangements, it will be appreciated that the carrier 14 c has a multi-part construction.

Fourth Mode: A fluid-transfer article having one or more heat activatable valves which control transfer of aerosol precursor to an activation surface of the article.

Aspects and embodiments of the fourth mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference. In general outline, one or more embodiments in accordance with the fourth mode of the present disclosure may provide a system for aerosol delivery in which an aerosol carrier may be inserted into a receptacle (e.g., a “heating chamber”) of an apparatus for initiating and maintaining release of an aerosol from the aerosol carrier. Another end, or another end portion, of the aerosol carrier may protrude from the apparatus and can be inserted into the mouth of a user for the inhalation of aerosol released from the aerosol carrier cartridge during operation of the apparatus.

Hereinafter, and for convenience only, “system for aerosol delivery” shall be referred to as “aerosol delivery system”. Referring now to FIG. 48 there is illustrated a perspective view of an aerosol delivery system 10 d comprising an aerosol generation apparatus 12 d operative to initiate and maintain release of aerosol from a fluid-transfer article in an aerosol carrier 14 d. In the arrangement of FIG. 48 the aerosol carrier 14 d is shown with a first end 16 d thereof and a portion of the length of the aerosol carrier 14 d located within a receptacle of the apparatus 12 d. A remaining portion of the aerosol carrier 14 d extends out of the receptacle. This remaining portion of the aerosol carrier 14 d, terminating at a second end 18 d of the aerosol carrier, is configured for insertion into a user's mouth. A vapor and/or aerosol is produced when a heater (not shown in FIG. 48 of the apparatus 12 d heats a fluid-transfer article in the aerosol carrier 14 d to release a vapor and/or an aerosol, and this can be delivered to the user, when the user sucks or inhales, via a fluid passage in communication with an outlet of the aerosol carrier 14 d from the fluid-transfer article to the second end 18 d.

The device 12 d also comprises air-intake apertures 20 d in the housing of the apparatus 12 d to provide a passage for air to be drawn into the interior of the apparatus 12 d (when the user sucks or inhales) for delivery to the first end 16 d of the aerosol carrier 14 d, so that the air can be drawn across an activation surface of a fluid-transfer article located within a housing of the aerosol carrier cartridge 14 d during use. Optionally, these apertures may be perforations in the housing of the apparatus 12 d.

A fluid-transfer article (not shown in FIG. 48 but described hereinafter with reference to FIGS. 52, 53, 54, 55, 56, and 57) is located within a housing of the aerosol carrier 14 d. The fluid-transfer article contains an aerosol precursor material, which may include at least one of: nicotine; a nicotine precursor material; a nicotine compound; and one or more flavorings. The fluid-transfer article is located within the housing of the aerosol carrier 14 d to allow air drawn into the aerosol carrier 14 d at, or proximal, the first end 16 d to flow across an activation surface of the fluid-transfer article. As air passes across the activation surface of the fluid-transfer article, an aerosol may be entrained in the air stream from a substrate forming the fluid-transfer article, e.g., via diffusion from the substrate to the air stream and/or via vaporization of the aerosol precursor material and release from the fluid-transfer article under heating.

The substrate forming the fluid-transfer article 33 d comprises a porous material where pores of the porous material hold, contain, carry, or bear the aerosol precursor material. In particular, the porous material of the fluid-transfer article may be a polymeric wicking material such as, for example, a sintered material. Particular examples of material suitable for the fluid-transfer article include: Polyetherimide (PEI); Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK); Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular Weight Polyethylene. Other suitable materials may comprise, for example, BioVyon™ (by Porvair Filtration Group Ltd) and materials available from Porex®. Further optionally, a substrate forming the fluid-transfer article may comprise Polypropylene (PP) or Polyethylene Terephthalate (PET). All such materials may be described as heat resistant polymeric wicking material in the context of the fourth mode of the present disclosure.

The aerosol carrier 14 d is removable from the apparatus 12 d so that it may be disposed of when expired. After removal of a used aerosol carrier 14 d, a replacement aerosol carrier 14 d can be inserted into the apparatus 12 d to replace the used aerosol carrier 14 d.

FIG. 49 is a cross-sectional side view illustration of a part of apparatus 12 d of the aerosol delivery system 10 d. The apparatus 12 d comprises a receptacle 22 d in which is located a portion of the aerosol carrier 14 d. In one or more optional arrangements, the receptacle 22 d may enclose the aerosol carrier 14 d. The apparatus 12 d also comprise a heater 24 d, which opposes an activation surface of the fluid-transfer article (not shown in FIG. 49 of the aerosol carrier 14 d when an aerosol carrier 14 d is located within the receptacle 22 d.

Air flows into the apparatus 12 d (in particular, into a closed end of the receptacle 22 d) via air-intake apertures 20 d. From the closed end of the receptacle 22 d, the air is drawn into the aerosol carrier 14 d (under the action of the user inhaling or sucking on the second end 18 d) and expelled at the second end 18 d. As the air flows into the aerosol carrier 14 d, it passes across the activation surface of the fluid-transfer article. Heat from the heater 24 d, which opposes the activation surface of the fluid-transfer article, causes vaporization of aerosol precursor material at the activation surface of the fluid-transfer article and an aerosol is created in the air flowing over the activation surface. Thus, through the application of heat in the region of the activation surface of the fluid-transfer article, an aerosol is released, or liberated, from the fluid-transfer article, and is drawn from the material of the aerosol carrier unit by the air flowing across the activation surface and is transported in the air flow to via outlet conduits (not shown in FIG. 49 in the housing of the aerosol carrier 14 d to the second end 18 d. The direction of air flow is illustrated by arrows in FIG. 49 To achieve release of the captive aerosol from the fluid-transfer article, the fluid-transfer article of the aerosol carrier 14 d is heated by the heater 24 d. As a user sucks or inhales on second end 18 d of the aerosol carrier 14 d, the aerosol released from the fluid-transfer article and entrained in the air flowing across the activation surface of the fluid-transfer article is drawn through the outlet conduits (not shown) in the housing of the aerosol carrier 14 d towards the second end 18 d and onwards into the user's mouth.

Turning now to FIG. 50 a cross-sectional side view of the aerosol delivery system 10 d is schematically illustrated showing the features described above in relation to FIGS. 48 and 49 in more detail. As can be seen, apparatus 12 d comprises a housing 26 d, in which are located the receptacle 22 d and heater 24 d. The housing 26 d also contains control circuitry (not shown) operative by a user, or upon detection of air and/or vapor being drawn into the device 12 d through air-intake apertures 20 d, i.e., when the user sucks or inhales. Additionally, the housing 26 d comprises an electrical energy supply 28 d, for example a battery. Optionally, the battery comprises a rechargeable lithium-ion battery. The housing 26 d also comprises a coupling 30 d for electrically (and optionally mechanically) coupling the electrical energy supply 28 d to control circuitry (not shown) for powering and controlling operation of the heater 24 d.

Responsive to activation of the control circuitry of apparatus 12 d, the heater 24 d heats the fluid-transfer article (not shown in FIG. 50 of aerosol carrier 14 d. This heating process initiates (and, through continued operation, maintains) release of vapor and/or an aerosol from the activation surface of the fluid-transfer article. The vapor and/or aerosol formed as a result of the heating process is entrained into a stream of air being drawn across the activation surface of the fluid-transfer article (as the user sucks or inhales). The stream of air with the entrained vapor and/or aerosol passes through the aerosol carrier 14 d via outlet conduits (not shown) and exits the aerosol carrier 14 d at second end 18 d for delivery to the user. This process is briefly described above in relation to FIG. 49 where arrows schematically denote the flow of the air stream into the device 12 d and through the aerosol carrier 14 d, and the flow of the air stream with the entrained vapor and/or aerosol through the aerosol carrier cartridge 14 d.

FIGS. 51 to 54 schematically illustrate the aerosol carrier 14 d in more detail (and, in FIGS. 52 to 54, features within the receptacle in more detail). FIG. 51 illustrates an exterior of the aerosol carrier 14 d, FIG. 52 illustrates internal components of the aerosol carrier 14 d in an optional configuration, and FIG. 53 illustrates internal components of the aerosol carrier 14 d in another optional configuration, and FIG. 54 illustrates another embodiment of the internal components of the aerosol carrier 14 d according to the fourth mode of the present disclosure.

FIG. 51 illustrates the exterior of the aerosol carrier 14 d, which comprises housing 32 d for housing said fluid-transfer article (not shown) and at least one other internal component. The particular housing 32 d illustrated in FIG. 51 comprises a tubular member, which may be generally cylindrical in form, and which is configured to be received within the receptacle of the apparatus. First end 16 d of the aerosol carrier 14 d is for location to oppose the heater of the apparatus, and second end 18 d (and the region adjacent the second end 18 d) is configured for insertion into a user's mouth. FIGS. 52 to 54 illustrate some optional arrangements corresponding to the internal components of the aerosol carrier 14 d and of the heater 24 d of apparatus 12 d.

As described above, the aerosol carrier 14 d comprises a fluid-transfer article 33 d. The aerosol carrier 14 d optionally may comprise a conduction element 37 d (as shown in FIG. 52 In one or more arrangements, the aerosol carrier 14 d is located within the receptacle of the apparatus such that the activation surface of the fluid-transfer article opposes the heater of the apparatus and receives heat directly from the heater of the apparatus. In an optional arrangement, such as illustrated in FIG. 52 for example, the aerosol carrier 14 d comprises a conduction element 37 d. When aerosol carrier 14 d is located within the receptacle of the apparatus such that the activation surface of the fluid-transfer article is located to oppose the heater of the apparatus, the conduction element is disposed between the heater 24 d and the activation surface of the fluid-transfer article. Heat may be transferred to the activation surface via conduction through conduction element 37 d (i.e., application of heat to the activation surface is indirect). Further components not shown in FIGS. 52 to 54 comprise: an inlet conduit, via which air can be drawn into the aerosol carrier 14 d; an outlet conduit, via which an air stream entrained with aerosol can be drawn from the aerosol carrier 14 d; a filter element; and a reservoir for storing aerosol precursor material and for providing the aerosol precursor material to the fluid-transfer article 33 d.

In FIGS. 52 to 54, the aerosol carrier is shown as comprising the fluid-transfer article 33 d located within housing 32 d. The material forming the article 33 d comprises a porous structure, where pore diameter size varies between one end of the fluid-transfer article 33 d and another end of the fluid-transfer article. In the illustrative examples of FIGS. 52 to 54, the pore diameter size gradually decreases from a first end remote from heater 24 d (the upper end as shown in the figure) to a second end proximal heater 24 d (the lower end as shown in the figure). Although the figure illustrates the pore diameter size changing in a step-wise manner from the first to the second end (i.e., a first region with pores having a diameter of a first size, a second region with pores having a diameter of a second, smaller size, and a third region with pores having a diameter of a third, yet smaller size), the change in pore size from the first end to the second end may be gradual rather than step-wise. This configuration of pores having a decreasing diameter size from the first end and second end can provide a wicking effect, which can serve to draw fluid from the first end to the second end of the fluid-transfer article 33 d. The fluid-transfer article 33 d comprises a first region 34 d for holding an aerosol precursor. In one or more arrangements, the first region 34 d of the fluid-transfer article 33 d comprises a reservoir for holding the aerosol precursor. The first region 34 d can be the sole reservoir of the aerosol carrier 14 d, or it can be arranged in fluid communication with a separate reservoir, where aerosol precursor is stored for supply to the first region 34 d.

The fluid-transfer article 33 d also comprises a second region 35 d. Aerosol precursor is drawn from the first region 34 d to the second region 35 d by the wicking effect of the substrate material forming the fluid-transfer article. Thus, the first region 34 d is configured to transfer the aerosol precursor to the second region 35 d of the article 33 d.

In FIGS. 52 and 53, there is a valve 36 d between the first region 34 d and the second region 35 d of the fluid-transfer article 33 d. The valve 36 d regulates fluid transfer between the first and second regions 34 d and 35 d to control transfer of the aerosol precursor to the second region 35 d. The valve 36 d is heat activatable and responds to a rise in temperature to open to allow aerosol precursor to pass therethrough.

In particular, when the fluid-transfer article is not heated (e.g., when the heater 24 d is at room temperature) the valve 36 d is closed. When the heater 24 d is activated, the heat that is generated by the heater 24 d is transferred to the valve 36 d, which activates to open one or more fluid flow-paths from the first region 34 d to the second region 35 d. Aerosol precursor may then pass to the second region 35 d.

For example, the valve 36 d may be made of a material with a plurality of small holes therethrough, with the material of the valve expanding when heated to dilate the holes to allow aerosol precursor to pass through the holes. If the holes dilate from 0.1 mm to 1 mm, when the temperature of the heater 24 d rises from room (ambient) temperature to its operating temperature, the holes should enlarge sufficiently from a state in which they substantially block passage of aerosol precursor to a state in which they allow relatively free flow of aerosol precursor therethrough. There would need to be enough holes in the material to allow sufficient aerosol precursor to pass to the second region 35 d when the heater 24 d is active to generate sufficient vapor for the user. The material of such a valve would normally need to be chosen to resist degradation due to the elevated temperatures to which it will be exposed (typically 200-250° C.).

Another possibility is to provide a plurality of valves in an array between the first and second regions 34 d and 35 d. Yet another possibility may be for there to be one, or a plurality, of electro-mechanical valves whose action is controlled by a heat sensor responsive to the heat generated by the heater 24 d. Other valve arrangements are also possible.

The first region 34 d of the fluid-transfer article, need not be of porous polymer material as described above. It may instead be a simple hollow reservoir filled with liquid aerosol precursor. The liquid aerosol precursor will then pass directly from the first region 34 d to the valve 36 d.

At the second end of fluid-transfer article 33 d, the surface of the second region 35 d defines an activation surface 38 d, which is disposed opposite a surface for conveying heat to the activation surface 38 d. In the illustrative examples of FIGS. 52 and 53, the opposing surface for conveying heat to the activation surface 38 d comprises a conduction element 37 d. The conduction element 37 d is located for thermal interaction with heater 24 d and is arranged to transfer heat from heater 24 d to the activation surface 38 d. As noted above, however, the conduction element 37 d may be absent in some arrangements, in which case the activation surface 38 d is disposed to receive heat directly from the heater 24 d.

The conduction element 37 d, if present, may comprise a thin film of thermally conductive material, such as, for example, a metal foil (for example, aluminum, brass, copper, gold, steel, silver, or an alloy comprising anyone of the foregoing together with thermally conductive plastics and/or ceramics).

The activation surface 38 d may be discontinuous such that at least one channel 40 d is formed between the activation surface 38 d and the conduction element 37 d (or the heater 24 d in the case of arrangements in which the conduction element 37 d is absent). In some arrangements, the discontinuities may be such that the activation surface 38 d is undulating.

In the illustrative examples of FIGS. 52 and 53, the activation surface 38 d comprises a plurality of grooves or valleys therein to form an undulating surface, the grooves or valleys being disposed in a parallel arrangement across the activation surface 38 d. Thus, there are a plurality of channels 40 d between the activation surface 38 d and the conduction element 37 d.

In the illustrative example of FIG. 52 the grooves or valleys in the activation surface 38 d provide alternating peaks and troughs that give rise to a “saw-tooth” type profile. In one or more optional arrangements, the activation surface may comprise a “castellated” type profile (i.e., a “square wave” type profile), for example, such as illustrated in the example of FIG. 6. In one or more optional arrangements, the activation surface may comprise a “sinusoidal” type profile. The profile may comprise a mixture of two or more of the above profiles given as illustrative examples.

In the illustrative examples of FIGS. 52 and 53, the first region 34 d of the fluid-transfer article 33 d is located at an “upstream” end of the fluid-transfer article 33 d and the second region 35 d is located at a downstream” end of the fluid-transfer article 33 d. That is, aerosol precursor is wicked, or is drawn, from the “upstream” end of the fluid-transfer article 33 d to the “downstream” end of the fluid-transfer article 33 d (as denoted by arrow D in FIG. 52).

The aerosol precursor is configured to release an aerosol and/or vapor upon heating. Thus, when the activation surface 38 d receives heat conveyed from heater 24 d, the aerosol precursor held at the activation surface 38 d is heated. The aerosol precursor, which is captively held in material of the fluid-transfer article at the activation surface 38 d is released into an air stream flowing through the channels 40 d between the conduction element 37 d and activation surface 38 d (or between the heater 24 d and the activation surface 38 d) as an aerosol and/or vapor.

The shape and/or configuration of the activation surface 38 d and the associated shape(s) and/or configuration(s) of the one or more channels 40 d formed between the activation surface 38 d and conduction element 37 d (or between the activation surface 38 d and heater 24 d) permit air to flow across the activation surface 38 d (through the one or more channels 40 d) and also increase the surface area of the activation surface 38 d of the fluid-transfer article 33 d that is available for contact with a flow of air across the activation surface 38 d.

In the embodiments of FIGS. 52 and 53, the valve 36 d is between the first region 34 d and the second region 35 d of the fluid-transfer article 33 d. FIG. 54 illustrates another embodiment of the fourth mode in which the valve 36 d forms the second region of the fluid-transfer article. Thus, in this embodiment, the valve is the closest part of the fluid-transfer article 33 d to the heater 24 d and the activation surface 38 d is formed by a surface of the valve 36 d. When the valve 36 d is closed, aerosol precursor cannot pass through the second region. When the heater is activated, thereby opening the valve 36 d, as the valve is activated by heat, aerosol precursor may then reach the activation surface 38 d.

Note that in FIG. 54 the first region of the fluid-transfer article is formed of parts 34 d and 35 d of different pore sizes. It would also be possible to have an arrangement in which the first region has only one part of a uniform pore size.

In the embodiment of FIG. 54 the valve 36 d may be made separable from the first region of the fluid-transfer article, i.e., there is no fixing of the valve 36 d to the second part 35 d. Since the aerosol precursor will be depleted, as the user uses the apparatus, it may be desirable to replace the first region formed by parts 34 d, 35 d. The separability of the valve 36 d means that the valve does not need to be replaced when replacing the first region.

In the embodiment of FIG. 54 there are no channels 40 d. However, there is an opening 41 d in the housing 32 d, the opening 41 d is in communication with the air-intake 20 d of the apparatus. A further opening 42 d communicates with a duct 43 d within the housing 32 d, which duct 43 d communicates with the second end 18 d. There is thus a fluid-flow path for air (hereafter referred to as an air-flow pathway) between openings 41 d and 42 d, linking the apertures 20 d from the second end 18 d of the aerosol carrier. That air-flow pathway extends between the activation surface 38 d and the conduction element 37 d of the heater 24 d. Thus, when the heater 24 d is activated, heat is transferred from the heater 24 d to the conduction element 37 d, and from there to the valve 36 d, which opens as it is heat-activatable, to allow aerosol precursor to pass therethrough, to the activation surface 38 d. At activation surface 38 d, aerosol precursor is heated to form vapor and/or aerosol. When the user sucks or inhales, air flows between the openings 41 d and 42 d, and flows along the air-flow pathway between the activation surface 38 d and the conduction element 37 d, and vapor and/or a mixture of aerosol and vapor is mixed with that air and then passes through the passageway 40 d to the second end 18 d.

In the arrangements shown in FIGS. 52 to 54, the apertures 41 d and 42 d are on opposite sides of the housing 32 d. FIGS. 55 and 56 show an alternative configuration, in which the fluid-transfer article is annular and the valve 36 d is then also annular. The arrangement of FIGS. 55 and 56 corresponds to the arrangement shown in FIGS. 52 and 53, in that there is a valve 36 d between the first region 34 d and second region 35 d of the fluid-transfer article. Thus, FIGS. 55 and 56 illustrate an aerosol carrier 14 d according to one or more possible arrangements in more detail. FIG. 55 is a cross-section side view illustration of the aerosol carrier 14 d and FIG. 56 is a perspective cross-section side view illustration of the aerosol carrier 14 d of FIG. 55 As can be seen from FIGS. 55 and 56, the aerosol carrier 14 d is generally tubular in form. The aerosol carrier 14 d comprises housing 32 d, which defines the external walls of the aerosol carrier 14 d and which defines therein a chamber in which are disposed the fluid-transfer article 33 d (adjacent the first end 16 d of the aerosol carrier 14 d) and internal walls defining the fluid communication pathway 49 d. Fluid communication pathway 49 d defines a fluid pathway for an outgoing air stream from the channels 40 d to the second end 18 d of the aerosol carrier 14 d. In the examples illustrated in FIGS. 55 and 56, the fluid-transfer article 33 d is an annular shaped element located around the fluid communication pathway 49 d.

In walls of the housing 32 d, there are provided inlet apertures 50 d to provide a fluid communication pathway for an incoming air stream to reach the fluid-transfer article 33 d, and particularly the one or more channels 40 d defined between the activation surface of the fluid-transfer article 33 d and the conduction element 37 d (or between the activation surface and the heater).

In the illustrated example of FIGS. 55 and 56, the aerosol carrier 14 d further comprises a filter element 52 d. The filter element 52 d is located across the fluid communication pathway 49 d such that an outgoing air stream passing through the fluid communication pathway 49 d passes through the filter element 52 d.

With reference to FIG. 56 when the heater 24 d is activated to open the valve 36 d, and a user sucks on a mouthpiece of the apparatus (or on the second end 18 d of the aerosol carrier 14 d, if configured as a mouthpiece), air is drawn into the carrier through inlet apertures 50 d extending through walls in the housing 32 d of the aerosol carrier 14 d. An incoming air stream 44 d from a first side of the aerosol carrier 14 d is directed to a first side of the activation surface 38 d of the fluid-transfer article 33 d (e.g., via a gas communication pathway within the housing of the carrier). An incoming air stream 45 d from a second side of the aerosol carrier 14 d is directed to a second side of the activation surface 38 d of the fluid-transfer article 33 d (e.g., via a gas communication pathway within the housing of the carrier). When the incoming air stream 44 d from the first side of the aerosol carrier 14 d reaches the first side of the activation surface 38 d, the incoming air stream 44 d from the first side of the aerosol carrier 14 d flows across the activation surface 38 d. Likewise, when the incoming air stream 45 d from the second side of the aerosol carrier 14 d reaches the second side of the activation surface 38 d, the incoming air stream 45 d from the second side of the aerosol carrier 14 d flows across the activation surface 38 d. The air streams from each side are denoted by dashed lines 46 d and 47 d in FIG. 56 As air streams 46 d and 47 d flow, since the heater 24 d is activated and the valve 36 d is open, aerosol precursor can reach the activation surface 38 d. Then aerosol precursor in the activation surface 38 d, across which the air streams 46 d and 47 d flow, is released from the activation surface 38 d by heat conveyed to the activation surface from the heater 24 d. Aerosol precursor released from the activation surface 38 d is entrained in air streams 46 d and 47 d.

In use, the heater 24 d of the apparatus 12 d conveys heat to the activation surface 38 d of the fluid-transfer article 33 d to raise a temperature of the activation surface 38 d to a sufficient temperature to release, or liberate, captive substances (i.e., the aerosol precursor) held at the activation surface 38 d of the fluid-transfer article 33 d to form a vapor and/or aerosol, which is drawn downstream across the activation surface 38 d of the fluid-transfer article 33 d. As the air streams 46 d and 47 d continue their passages, more released aerosol precursor is entrained within the air streams 46 d and 47 d. When the air streams 46 d and 47 d entrained with aerosol precursor meet at a mouth of the fluid communication pathway 49 d, they enter the fluid communication pathway 49 d and continue until they pass through filter element 52 d and fluid communication pathway 49 d, either as a single outgoing air stream, or as separate outgoing air streams 48 d (as shown). The outgoing air streams 46 d are directed to an outlet, from where it can be inhaled by the user directly (if the second end 18 d of the aerosol capsule 14 d is configured as a mouthpiece), or via a mouthpiece. The outgoing air streams 46 d entrained with aerosol precursor are directed to the outlet (e.g., via a gas communication pathway within the housing of the carrier).

In FIGS. 55 and 56 the heat activatable valve 36 d is between the first and second regions 34 d and 35 d, as in the arrangement so FIGS. 52 and 53. Alternatively, the valve 36 d may form the second region, as in the embodiment of FIG. 54 In either case, the valve 36 d controls the movement of the aerosol precursor to the activation surface 38 d.

FIG. 57 is an exploded perspective view illustration of a kit-of-parts for assembling an aerosol delivery system 10 d.

Fifth Mode: An aerosol-generation apparatus having a heater which has a heating region in abutting unbonded contact with a wick of a fluid-transfer article.

Aspects and embodiments of the fifth mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

In general outline, one or more embodiments in accordance with the fifth mode of the present disclosure may provide a system for aerosol delivery in which an aerosol carrier may be inserted into a receptacle (e.g., a “heating chamber”) of an apparatus for initiating and maintaining release of an aerosol from the aerosol carrier. Another end, or another end portion, of the aerosol carrier may protrude from the apparatus and can be inserted into the mouth of a user for the inhalation of aerosol released from the aerosol carrier during operation of the apparatus.

Hereinafter, and for convenience only, “system for aerosol delivery” shall be referred to as “aerosol delivery system”.

Referring now to FIG. 58, there is illustrated a perspective view of an aerosol delivery system 10 e comprising an aerosol generation apparatus 12 e operative to initiate and maintain release of aerosol from a fluid-transfer article in an aerosol carrier 14 e. In the arrangement of FIG. 58, the aerosol carrier 14 e is shown with a first end 16 e thereof and a portion of the length of the aerosol carrier 14 e located within a receptacle of the apparatus 12 e. A remaining portion of the aerosol carrier 14 e extends out of the receptacle. This remaining portion of the aerosol carrier 14 e, terminating at a second end 18 e of the aerosol carrier, is configured for insertion into a user's mouth. A vapor and/or aerosol is produced when a heater (not shown in FIG. 58) of the apparatus 12 e heats a fluid-transfer article in the aerosol carrier 14 e to release a vapor and/or an aerosol, and this can be delivered to the user, when the user sucks or inhales, via a fluid passage in communication with an outlet of the aerosol carrier 14 e from the fluid-transfer article to the second end 18 e.

The device 12 e also comprises air-intake openings 20 e in the housing of the apparatus 12 e to provide a passage for air to be drawn into the interior of the apparatus 12 e (when the user sucks or inhales) for delivery to the first end 16 e of the aerosol carrier 14 e, so that the air can be drawn to the wick of a fluid-transfer article located within a housing of the aerosol carrier 14 e during use. Optionally, these openings may be perforations in the housing of the apparatus 12 e.

A fluid-transfer article (not shown in FIG. 58 but described hereinafter with reference to FIGS. 62 to 65 is located within a housing of the aerosol carrier 14 e. The fluid-transfer article contains an aerosol precursor material, which may include at least one of: nicotine; a nicotine precursor material; a nicotine compound; and one or more flavorings. The fluid-transfer article is located within the housing of the aerosol carrier 14 e to allow air drawn into the aerosol carrier 14 e at, or proximal, the first end 16 e to flow to a wick of the fluid-transfer article. As air passes the wick of the fluid-transfer article, an aerosol may be entrained in the air stream from a substrate forming the fluid-transfer article, e.g., via diffusion from the substrate to the air stream and/or via vaporization of the aerosol precursor material and release from the fluid-transfer article under heating.

Part of the fluid-transfer article 34 e may comprise a porous material where pores of the porous material hold, contain, carry, or bear the aerosol precursor material. In particular, the porous material of the fluid-transfer article is a porous polymer material such as, for example, a sintered material. Particular examples of material suitable for the fluid-transfer article include: Polyetherimide (PEI); Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK); Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular Weight Polyethylene. Other suitable materials may comprise, for example, BioVyon™ (by Porvair Filtration Group Ltd) and materials available from Porex®. Further optionally, a substrate forming the fluid-transfer article may comprise Polypropylene (PP) or Polyethylene Terephthalate (PET). All such materials may be described as heat resistant polymeric wicking material in the context of the fifth mode of the present disclosure.

Alternatively, the fluid-transfer article 34 e may have an open reservoir for aerosol precursor, with a suitable seal to prevent leakage.

The aerosol carrier 14 e is removable from the apparatus 12 e so that it may be disposed of when expired. After removal of a used aerosol carrier 14 e, a replacement aerosol carrier 14 e can be inserted into the apparatus 12 e to replace the used aerosol carrier 14 e. FIG. 59 is a cross-sectional side view illustration of a part of apparatus 12 e of the aerosol delivery system 10 e. The apparatus 12 e comprises a receptacle 22 e in which is located a portion of the aerosol carrier 14 e. In one or more optional arrangements, the receptacle 22 e may enclose the aerosol carrier 14 e. The apparatus 12 e also comprises a heater 24 e, which has a heating region in contact with part of a wick of the fluid-transfer article (not shown in FIG. 59) of the aerosol carrier 14 e when an aerosol carrier 14 e is located within the receptacle 22 e.

Air flows into the apparatus 12 e (in particular, into a closed end of the receptacle 22 e) via air-intake openings 20 e. From the closed end of the receptacle 22 e, the air is drawn into the aerosol carrier 14 e (under the action of the user inhaling or sucking on the second end 18 e) and expelled at the second end 18 e. As the air flows into the aerosol carrier 14 e, it passes across the heating region of the heater 24 e and around the wick. Heat from the heating region of the heater 24 e, which is in contact with the wick of the fluid-transfer article, causes vaporization of aerosol precursor material in the wick of the fluid-transfer article and an aerosol is created in the air flowing over the heating surface. Thus, through the application of heat, aerosol is released or liberated from the wick of the fluid-transfer article and is drawn from the material of the aerosol carrier unit by the air flowing past the heating region of the heater and is transported in the air flow to the user via outlet conduits (not shown in FIG. 59) in the housing of the aerosol carrier 14 e to the second end 18 e. The direction of air flow is illustrated by arrows in FIG. 59.

To achieve release of the captive aerosol from the fluid-transfer article, the fluid-transfer article of the aerosol carrier 14 e, and in particular the wick thereof, is heated by the heater 24 e. As a user sucks or inhales on second end 18 e of the aerosol carrier 14 e, the aerosol released from the wick of the fluid-transfer article and entrained in the air flowing past the heating region of the heater 24 e is drawn through the outlet conduits (not shown) in the housing of the aerosol carrier 14 e towards the second end 18 e and onwards into the user's mouth.

Turning now to FIG. 60, a cross-sectional side view of the aerosol delivery system 10 e is schematically illustrated showing the features described above in relation to FIGS. 58 and 59 in more detail. As can be seen, apparatus 12 e comprises a housing 26 e, in which are located the receptacle 22 e and heater 24 e. The housing 26 e also contains control circuitry (not shown) operative by a user, or upon detection of air and/or vapor being drawn into the device 12 e through air-intake openings 20 e, i.e., when the user sucks or inhales. Additionally, the housing 26 e comprises an electrical energy supply 28 e, for example a battery. Optionally, the battery comprises a rechargeable lithium-ion battery. The housing 26 e also comprises a coupling 30 e for electrically (and optionally mechanically) coupling the electrical energy supply 28 e to control circuitry (not shown) for powering and controlling operation of the heater 24 e.

Responsive to activation of the control circuitry of apparatus 12 e, the heater 24 e heats the wick of the fluid-transfer article (not shown in FIG. 60) of aerosol carrier 14 e. This heating process initiates (and, through continued operation, maintains) release of vapor and/or an aerosol from the activation surface of the fluid-transfer article. The vapor and/or aerosol formed as a result of the heating process is entrained into a stream of air being drawn past the heating region of the heater (as the user sucks or inhales). The stream of air with the entrained vapor and/or aerosol passes through the aerosol carrier 14 e via outlet conduits (not shown) and exits the aerosol carrier 14 e at second end 18 e for delivery to the user. This process is briefly described above in relation to FIG. 59, where arrows schematically denote the flow of the air stream into the device 12 e and through the aerosol carrier 14 e, and the flow of the air stream with the entrained vapor and/or aerosol through the aerosol carrier 14 e. FIGS. 61 to 63 schematically illustrate the aerosol carrier 14 e in more detail (and, in FIGS. 62 and 63, features within the receptacle in more detail). FIG. 61 illustrates an exterior of the aerosol carrier 14 e, FIG. 62 illustrates internal components of the aerosol carrier 14 e in one optional configuration, and FIG. 63 illustrates a possible configuration of the heater 24 e. FIG. 61 illustrates the exterior of the aerosol carrier 14 e, which comprises housing 32 e for housing said fluid-transfer article (not shown). The particular housing 32 e illustrated in FIG. 61 comprises a tubular member, which may be generally cylindrical in form, and which is configured to be received within the receptacle of the apparatus. First end 16 e of the aerosol carrier 14 e is for location to oppose the heater of the apparatus, and second end 18 e (and the region adjacent the second end 18 e) is configured for insertion into a user's mouth.

FIG. 62 illustrates some internal components of the aerosol carrier 14 e and of the heater 24 e of apparatus 12 e, in in one embodiment of the disclosure. Further components not shown in FIG. 62 comprise: an inlet conduit, via which air can be drawn into the aerosol carrier 14 e; an outlet conduit, via which an air stream entrained with aerosol can be drawn from the aerosol carrier 14 e; a filter element; and a reservoir for storing aerosol precursor material and for providing the aerosol precursor material to the fluid-transfer article 34 e.

In FIG. 62, the aerosol carrier is shown as comprising the fluid-transfer article 34 e located within housing 32 e. The fluid-transfer article 34 e comprises a first region 35 e holding an aerosol precursor. In one or more arrangements, the first region 35 e of the fluid-transfer article 34 e comprises a reservoir for holding the aerosol precursor. The first region 35 e can be the sole reservoir of the aerosol carrier 14 e, or it can be arranged in fluid communication with a separate reservoir, where aerosol precursor is stored for supply to the first region 35 e. The material forming the first region 35 e may comprise a porous structure, whose pore diameter size varies between one end of the first region 35 e and another end of the first region 35 e. The pore diameter size may decrease from a first end remote from heater 24 e (the upper end is as shown in the figure) to a second end. The change in pore size in the first region 35 e may be gradual rather than stepwise. This configuration of pores having a decreasing diameter size can provide a wicking effect, which can serve to draw fluid through the first region 35 e.

Particular examples of material suitable for the first region 35 e of the fluid-transfer article include: Polyetherimide (PEI); Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK); Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular Weight Polyethylene. Other suitable materials may comprise, for example, BioVyon™ (by Porvair Filtration Group Ltd) and materials available from Porex®. Further optionally, a substrate forming the fluid-transfer article may comprise Polypropylene (PP) or Polyethylene Terephthalate (PET). Alternatively, the first region 35 e may be a simple liquid reservoir in the form of an empty tank for the receipt of liquid aerosol precursor, rather than porous material for holding the aerosol precursor.

The fluid-transfer article also comprises a second region 36 e, acting as a seal for the first region 35 e. This is particularly important if first region 35 e is a tank containing liquid. The second region 36 e thus prevents unwanted escape of aerosol precursor from the first region 35 e.

As mentioned above, the fluid-transfer article also includes a wick 44 e. In the arrangement shown in FIG. 62, the wick 44 e is flexible and U-shaped, with the arms of the U-shape extending through the second region 36 e into the first region 35 e. The wick 44 e is absorbent, so that its ends absorb aerosol precursor from the first region 35 e. For example, the wick 44 e may be of a cord material. The aerosol precursor will pass from the first region 35 e through and along the wick 44 e towards the base of the U-shape of the wick 44 e. As illustrated in FIG. 62, the base of the U-shape of the flexible wick 44 e is in contact with the heater 24 e at a heating region. Thus, when the heater 24 e is active, heat will be transferred from the heater 24 e to the wick 44 e, thereby heating the aerosol precursor which has been absorbed by the wick 44 e. The heating of the wick 44 e will release aerosol precursor from the wick 44 e, as a vapor and/or a mixture of vapor and aerosol.

The configuration of the wick 44 e is not limited to arrangement shown in FIG. 62 For example, it may be a relatively rigid body which forms an end for the region 35 e. The second region 36 e may then not be necessary. In such a case, the wick may be made of a porous polymer material, e.g., those referred to above as heat resistant polymeric wicking materials.

FIG. 62 also illustrates an opening 40 e in a further housing 33 e, which opening 40 e is in communication with the air-intake openings 20 e. A further opening 40 e communicates with a duct 41 e within the housing 32 e, which duct 41 e communicates with the second end 18 e. The further housing 33 e may be integral with the housing 26 e containing the electrical energy supply 28 e.

There is thus a fluid-flow path for air (hereinafter referred to as an air-flow pathway) between openings 39 e and 40 e, linking the openings 20 e and the second end 18 e of the aerosol carrier. When the user sucks or inhales, air is drawn along the air-flow pathway, past a heating region 38 e of the heater 24 e.

One or more droplets of the aerosol precursor will be released from the wick 44 e as it is heated, to release vapor or a mixture of aerosol and vapor into the air flowing in the air-flow pathway between the openings 39 e and 40 e. The vapor or mixture passes, as the user sucks and inhales, to the second end 18 e. FIG. 63 shows an embodiment of the heater 24 e in more detail. As illustrated, the heater has a heating region 38 e comprising alternating straight sections 42 e and U-shaped sections 43 e, so that heating region 38 e is convoluted. This enables good contact to be made between the heating region 38 e and the wick 44 e, whilst allowing for variations in their relative positions. Hence, when the housings 32 e and 33 e are joined, the contact between the wick 44 e and the heating region 38 e is not dependent on the precise positioning or orientation of the housings 32 e and 33 e.

The heating region 38 e is supported on upright sections 25 e of the heater 24 e, which upright sections 25 e may extend from the coupling 30 e shown in FIG. 60 The straight and U-shaped sections 42 e, 43 e of the heating region 38 e may be arranged so that, in the absence of deformation, they lie in a plane, whereby the heating region 38 e is flat prior to contact with the wick 44 e. That contact may then deform the heating region 38 e so that it becomes somewhat concave, thereby conforming at least partially to the shape of the wick 44 e. Alternatively, the heating region 38 e may be curved, either concave or convex, in the absence of deformation. For example, a convex arrangement, curved towards the wick 44 e, may assist in ensuring good contact between the wick 44 e and the heating region 38 e.

It is possible for the whole of the heating region 38 e to be flexible, so both the straight sections 42 e and the U-shaped sections 43 e are flexible. Alternatively, however, only the U-shaped sections 43 e may be flexible, and the straight sections 42 e may be rigid, as this would still allow the heating region 38 e to conform generally to the wick 44 e. The opposite arrangement would also be possible, namely rigid U-shaped sections 43 e and flexible straight sections 42 e. In either case, it is desirable that the flexibility of the heating region 38 e of the heater 24 e is a resilient flexibility, both to allow the heating region 38 e to return to its original shape if the fluid-transfer article, and hence the wick, is removed from the rest of the apparatus, and also because the resilience will ensure that contact is not lost, e.g., due to impact on, or shaking of, the apparatus.

The deformation of the heating region 38 e, due to its flexibility, will have the effect of increasing surface area contact between the heating region 38 e and the wick 44 e, which may improve the rate of vaporization of the aerosol precursor. This may be improved further if the wick 44 e is itself somewhat flexible.

In the illustrative examples of FIG. 62, the first region 35 e of the fluid-transfer article 34 e is located at an “upstream” end of the fluid-transfer article 34 e and the flexible wick 44 e is located at a downstream” end of the fluid-transfer article 34 e. That is, aerosol precursor is wicked, or is drawn, from the “upstream” end of the fluid-transfer article 34 e to the “downstream” end of the fluid-transfer article 34 e (as denoted by arrow Ain FIG. 62).

In the arrangement of FIG. 62, the housing 32 e contains the first and second parts 35 e, 36 e of the fluid-transfer article, and also supports the wick 44 e. The heater 24 e is supported by the further housing 33 e which has the openings 39 e and 40 e therein, Housings 32 e and 33 e are separable, for example along the line B-B in FIG. 62 Thus, the housing 32 e and hence the fluid-transfer article 34 e may be removed from the rest of the structure, for example when the aerosol precursor therein has been depleted. The aerosol precursor may be re-filled, or the carrier 14 e replaced with another filled one. As mentioned above, the heating region 38 e is flexible, and is preferably resilient. Then, when the carrier 14 e is in place, and the housing 32 e is in the position shown in FIG. 62 relative to the housing 33 e, the contact between the wick 44 e and the heating region 38 e will be resilient, so that the heating region 38 e is biased into contact with the wick 44 e to ensure good heat transfer to the wick 44 e. In the arrangements shown in FIGS. 62 and 63, the openings 39 e and 40 e are on opposite sides of the housing 32 e. FIGS. 64 and 65 show an alternative configuration, in which the fluid-transfer article is annular, and the first and second regions 35 e and 36 e are also annular. In FIGS. 64 and 65, the second region 36 e is illustrated in a position corresponding to that shown in FIGS. 62 and 63, where it is spaced from the heating region 38 e of the heater 24 e. This enables the air flow in the apparatus to be illustrated. Thus, FIGS. 64 and 65 illustrate an aerosol carrier 14 e according to one or more possible arrangements in more detail. FIG. 64 is a cross-section side view illustration of the aerosol carrier 14 e and FIG. 65 is a perspective cross-section side view illustration of the aerosol carrier 14 e.

As can be seen from FIGS. 64 and 65, the aerosol carrier 14 e is generally tubular in form. The aerosol carrier 14 e comprises housing 32 e, which defines the external walls of the aerosol carrier 14 e and which defines therein a chamber in which are disposed the fluid-transfer article 34 e (adjacent the first end 16 e of the aerosol carrier 14 e) and internal walls defining the fluid communication pathway 50 e. Fluid communication pathway 50 e defines a fluid pathway for an outgoing air stream from the ducts 41 e to the second end 18 e of the aerosol carrier 14 e. In the examples illustrated in FIGS. 64 and 65, the fluid-transfer article 34 e is an annular shaped element located around the fluid communication pathway 50 e. A plurality of wicks 44 e may be provided around the fluid communication pathway 50 e, or there may be a single wick in the form of a toroid with a gap therein to form arms which pass through the second region 36 e of the fluid-transfer article and extend into the first part 35 e to receive aerosol precursor therefrom. Similarly, there may be a plurality of heaters 24 e around the fluid communication pathway 50 e, each being generally similar to the arrangement shown in FIG. 63, or there may be single heater with a toroidal heating region 38 e.

In the walls of the housing 33 e, there are provided inlet openings 51 e to provide a fluid communication pathway for an incoming air stream to reach the fluid-transfer article 34 e, and particularly the air-flow pathway defined past the heating region 38 e.

In the illustrated example of FIGS. 64 and 65, the aerosol carrier 14 e further comprises a filter element 52 e. The filter element 52 e is located across the fluid communication pathway 50 e such that an outgoing air stream passing through the fluid communication pathway 50 e passes through the filter element 52 e. With reference to FIG. 65, when a user sucks on a mouthpiece of the apparatus (or on the second end 18 e of the aerosol carrier 14 e, if configured as a mouthpiece), air is drawn into the carrier through inlet openings 51 e extending through walls in the housing 33 e.

An incoming air stream 45 e from a first side of the aerosol carrier 14 e is directed to a first side of the second part 36 e of the fluid-transfer article 34 e (e.g., via a gas communication pathway within the housing of the carrier). An incoming air stream 46 e from a second side of the aerosol carrier 14 e is directed to a second side of the second part 36 e of the fluid-transfer article 34 e (e.g., via a gas communication pathway within the housing of the carrier). When the incoming air stream 45 e from the first side of the aerosol carrier 14 e reaches the first side of the second part 36 e, the incoming air stream 45 e from the first side of the aerosol carrier 14 e flows past the heating region 38 e. Likewise, when the incoming air stream 46 e from the second side of the aerosol carrier 14 e reaches the second side of the second part 36 e, the incoming air stream 46 e from the second side of the aerosol carrier 14 e flows past the heating region 38 e. The air streams from each side are denoted by dashed lines 47 e and 48 e in FIG. 65 As these air streams 47 e and 48 e flow, aerosol precursor in the flexible wick 44 e or on the heating region 38 e is entrained in air streams 47 e and 48 e.

In use, the heater 24 e of the apparatus 12 e raises a temperature of the wick 44 e, to a sufficient temperature to release, or liberate, captive substances (i.e., the aerosol precursor) to form a vapor and/or aerosol, which is drawn downstream. As the air streams 47 e and 48 e continue their passages, more released aerosol precursor is entrained within the air streams 47 e and 48 e. When the air streams 47 e and 48 e entrained with aerosol precursor meet at a mouth of the outlet fluid communication pathway 50 e, they enter the outlet fluid communication pathway 50 e and continue until they pass through filter element 52 e and exit outlet fluid communication pathway 50 e, either as a single outgoing air stream, or as separate outgoing air streams 49 e (as shown). The outgoing air streams 49 e are directed to an outlet, from where it can be inhaled by the user directly (if the second end 18 e of the aerosol carrier 14 e is configured as a mouthpiece), or via a mouthpiece. The outgoing air streams 49 e entrained with aerosol precursor are directed to the outlet (e.g., via a gas communication pathway within the housing of the carrier).

In FIGS. 64 and 65, the housing 32 e is separable from the housing 33 e, as in the arrangements of FIGS. 62 and 63. This enables the carrier 14 e, hence the fluid-transfer article 34 e to be removed from the rest of the structure and a depleted aerosol precursor to be replaced.

In any of the embodiments described above the second region 36 e may have a thickness of less than 5 mm. In other embodiments it may have a thickness of: less than 3.5 mm, less than 3 mm, less than 2.5 mm, less than 2 mm, less than 1.9 mm, less than 1.8 mm, less than 1.7 mm, less than 1.6 mm, less than 1.5 mm, less than 1.4 mm, less than 1.3 mm, less than 1.2 mm, less than 1.1 mm, less than 1 mm, less than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less than 0.6 mm, less than 0.5 mm, less than 0.4 mm, less than 0.3 mm, less than 0.2 mm, or less than 0.1 mm.

FIG. 66 is an exploded perspective view illustration of a kit-of-parts for assembling an aerosol delivery system 10 e.

As will be appreciated, in the arrangements described above, the fluid-transfer article 34 e is provided within a housing 32 e of the aerosol carrier 14 e. In such arrangements, the housing of the carrier 14 e serves to protect the aerosol precursor-containing fluid-transfer article 34 e, whilst also allowing the carrier 14 e to be handled by a user without his/her fingers coming into contact with the aerosol precursor liquid retained therein.

Sixth Mode: An aerosol-generation apparatus having a heater which has a heating region in contact with a wick of a fluid-transfer article.

Aspects and embodiments of the sixth mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

In general outline, one or more embodiments in accordance with the sixth mode of the present disclosure may provide a system for aerosol delivery in which an aerosol carrier may be inserted into a receptacle (e.g., a “heating chamber”) of an apparatus for initiating and maintaining release of an aerosol from the aerosol carrier.

Another end, or another end portion, of the aerosol carrier may protrude from the apparatus and can be inserted into the mouth of a user for the inhalation of aerosol released from the aerosol carrier cartridge during operation of the apparatus.

Hereinafter, and for convenience only, “system for aerosol delivery” shall be referred to as “aerosol delivery system”.

Referring now to FIG. 67, there is illustrated a perspective view of an aerosol delivery system 10 f comprising an aerosol generation apparatus 12 f operative to initiate and maintain release of aerosol from a fluid-transfer article in an aerosol carrier 14 f. In the arrangement of FIG. 67, the aerosol carrier 14 f is shown with a first end 16 f thereof and a portion of the length of the aerosol carrier 14 f located within a receptacle of the apparatus 12 f. A remaining portion of the aerosol carrier 14 f extends out of the receptacle. This remaining portion of the aerosol carrier 14 f, terminating at a second end 18 f of the aerosol carrier, is configured for insertion into a user's mouth. A vapor and/or aerosol is produced when a heater (not shown in FIG. 67) of the apparatus 12 f heats a fluid-transfer article in the aerosol carrier 14 f to release a vapor and/or an aerosol, and this can be delivered to the user, when the user sucks or inhales, via a fluid passage in communication with an outlet of the aerosol carrier 14 f from the fluid-transfer article to the second end 18 f.

The device 12 f also comprises air-intake apertures 20 f in the housing of the apparatus 12 f to provide a passage for air to be drawn into the interior of the apparatus 12 f (when the user sucks or inhales) for delivery to the first end 16 f of the aerosol carrier 14 f, so that the air can be drawn to the wick of a fluid-transfer article located within a housing of the aerosol carrier cartridge 14 f during use. Optionally, these apertures may be perforations in the housing of the apparatus 12 f. A fluid-transfer article (not shown in FIG. 67 but described hereinafter with reference to FIGS. 71 to 75 is located within a housing of the aerosol carrier 14 f. The fluid-transfer article contains an aerosol precursor material, which may include at least one of: nicotine; a nicotine precursor material; a nicotine compound; and one or more flavorings. The fluid-transfer article is located within the housing of the aerosol carrier 14 f to allow air drawn into the aerosol carrier 14 f at, or proximal, the first end 16 f to flow to a wick of the fluid-transfer article. As air passes the wick of the fluid-transfer article, an aerosol may be entrained in the air stream from a substrate forming the fluid-transfer article, e.g., via diffusion from the substrate to the air stream and/or via vaporization of the aerosol precursor material and release from the fluid-transfer article under heating. Part of the fluid-transfer article 34 f may comprise a porous material where pores of the porous material hold, contain, carry, or bear the aerosol precursor material. In particular, the porous material of the fluid-transfer article is a porous polymer material such as, for example, a sintered material. Particular examples of material suitable for the fluid-transfer article include: Polyetherimide (PEI); Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK); Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular Weight Polyethylene. Other suitable materials may comprise, for example, BioVyon™ (by Porvair Filtration Group Ltd) and materials available from Porex®. Further optionally, a substrate forming the fluid-transfer article may comprise Polypropylene (PP) or Polyethylene Terephthalate (PET). All such materials may be described as heat resistant polymeric wicking material in the context of the sixth mode of the present disclosure.

Alternatively, the fluid-transfer article 34 f may have an open reservoir for aerosol precursor, with a suitable seal to prevent leakage.

The aerosol carrier 14 f is removable from the apparatus 12 f so that it may be disposed of when expired. After removal of a used aerosol carrier 14 f, a replacement aerosol carrier 14 f can be inserted into the apparatus 12 f to replace the used aerosol carrier 14 f.

FIG. 68 is a cross-sectional side view illustration of a part of apparatus 12 f of the aerosol delivery system 10 f. The apparatus 12 f comprises a receptacle 22 f in which is located a portion of the aerosol carrier 14 f. In one or more optional arrangements, the receptacle 22 f may enclose the aerosol carrier 14 f. The apparatus 12 f also comprises a heater 24 f, which has a heating region in contact with part of a wick of the fluid-transfer article (not shown in FIG. 68) of the aerosol carrier 14 f when an aerosol carrier 14 f is located within the receptacle 22 f.

Air flows into the apparatus 12 f (in particular, into a closed end of the receptacle 22 f) via air-intake apertures 20 f. From the closed end of the receptacle 22 f, the air is drawn into the aerosol carrier 14 f (under the action of the user inhaling or sucking on the second end 18 f) and expelled at the second end 18 f. As the air flows into the aerosol carrier 14 f, it passes across the heating region of the heater 24 f and around the wick. Heat from the heating region of the heater 24 f, which is in contact with the wick of the fluid-transfer article, causes vaporization of aerosol precursor material in the wick of the fluid-transfer article and an aerosol is created in the air flowing over the heating surface. Thus, through the application of heat, aerosol is released or liberated from the wick of the fluid-transfer article and is drawn from the material of the aerosol carrier unit by the air flowing past the heating region of the heater and is transported in the air flow to the user via outlet conduits (not shown in FIG. 68) in the housing of the aerosol carrier 14 f to the second end 18 f. The direction of air flow is illustrated by arrows in FIG. 68.

To achieve release of the captive aerosol from the fluid-transfer article, the fluid-transfer article of the aerosol carrier 14 f, and in particular the wick thereof, is heated by the heater 24 f. As a user sucks or inhales on second end 18 f of the aerosol carrier 14 f, the aerosol released from the wick of the fluid-transfer article and entrained in the air flowing past the heating region of the heater 24 f is drawn through the outlet conduits (not shown) in the housing of the aerosol carrier 14 f towards the second end 18 f and onwards into the user's mouth.

Turning now to FIG. 69, a cross-sectional side view of the aerosol delivery system 10 f is schematically illustrated showing the features described above in relation to FIGS. 67 and 68 in more detail. As can be seen, apparatus 12 f comprises a housing 26 f, in which are located the receptacle 22 f and heater 24 f. The housing 26 f also contains control circuitry (not shown) operative by a user, or upon detection of air and/or vapor being drawn into the device 12 f through air-intake apertures 20 f, i.e., when the user sucks or inhales. Additionally, the housing 26 f comprises an electrical energy supply 28 f, for example a battery. Optionally, the battery comprises a rechargeable lithium-ion battery. The housing 26 f also comprises a coupling 30 f for electrically (and optionally mechanically) coupling the electrical energy supply 28 f to control circuitry (not shown) for powering and controlling operation of the heater 24 f.

Responsive to activation of the control circuitry of apparatus 12 f, the heater 24 f heats the wick of the fluid-transfer article (not shown in FIG. 69) of aerosol carrier 14 f. This heating process initiates (and, through continued operation, maintains) release of vapor and/or an aerosol from the activation surface of the fluid-transfer article. The vapor and/or aerosol formed as a result of the heating process is entrained into a stream of air being drawn past the heating region of the heater (as the user sucks or inhales). The stream of air with the entrained vapor and/or aerosol passes through the aerosol carrier 14 f via outlet conduits (not shown) and exits the aerosol carrier 14 f at second end 18 f for delivery to the user. This process is briefly described above in relation to FIG. 68, where arrows schematically denote the flow of the air stream into the device 12 f and through the aerosol carrier 14 f, and the flow of the air stream with the entrained vapor and/or aerosol through the aerosol carrier cartridge 14 f.

FIGS. 70 to 73 schematically illustrate the aerosol carrier 14 f in more detail (and, in FIGS. 71 to 73, features within the receptacle in more detail). FIG. 70 illustrates an exterior of the aerosol carrier 14 f, FIG. 71 illustrates internal components of the aerosol carrier 14 f in one optional configuration, and FIGS. 72 and 73 illustrate possible options for the heater 24 f.

FIG. 70 illustrates the exterior of the aerosol carrier 14 f, which comprises housing 32 f for housing said fluid-transfer article (not shown). The particular housing 32 f illustrated in FIG. 70 comprises a tubular member, which may be generally cylindrical in form, and which is configured to be received within the receptacle of the apparatus. First end 16 f of the aerosol carrier 14 f is for location to oppose the heater of the apparatus, and second end 18 f (and the region adjacent the second end 18 f) is configured for insertion into a user's mouth.

FIG. 71 illustrates some internal components of the aerosol carrier 14 f and of the heater 24 f of apparatus 12 f, in in one embodiment of the disclosure.

Further components not shown in FIG. 71 comprise: an inlet conduit, via which air can be drawn into the aerosol carrier 14 f; an outlet conduit, via which an air stream entrained with aerosol can be drawn from the aerosol carrier 14 f; a filter element; and a reservoir for storing aerosol precursor material and for providing the aerosol precursor material to the fluid-transfer article 34 f.

In FIG. 71, the aerosol carrier is shown as comprising the fluid-transfer article 34 f located within housing 32 f. The fluid-transfer article 34 f comprises a first region 35 f holding an aerosol precursor. In one or more arrangements, the first region of 34 a of the fluid-transfer article 34 f comprises a reservoir for holding the aerosol precursor. The first region 35 f can be the sole reservoir of the aerosol carrier 14 f, or it can be arranged in fluid communication with a separate reservoir, where aerosol precursor is stored for supply to the first region 35 f. The material forming the first region of 34 a may comprise a porous structure, whose pore diameter size varies between one end of the first region 35 f and another end of the first region 35 f. The pore diameter size may decrease from a first end remote from heater 24 f (the upper end is as shown in the figure) to a second end. The change in pore size in the first region 35 f may be gradual rather than stepwise. This configuration of pores having a decreasing diameter size can provide a wicking effect, which can serve to draw fluid through the first region 35 f.

Particular examples of material suitable for the first region 35 f of the fluid-transfer article include: Polyetherimide (PEI); Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK); Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular Weight Polyethylene. Other suitable materials may comprise, for example, BioVyon™ (by Porvair Filtration Group Ltd) and materials available from Porex®. Further optionally, a substrate forming the fluid-transfer article may comprise Polypropylene (PP) or Polyethylene Terephthalate (PET).

Alternatively, the first region 35 f may be a simple liquid reservoir in the form of an empty tank for the receipt of liquid aerosol precursor, rather than porous material for holding the aerosol precursor.

The fluid-transfer article also comprises a second region 36 f, acting as a seal for the first region 35 f. This is particularly important if first region 35 f is a tank containing liquid. The second region 36 f thus prevents unwanted escape of aerosol precursor from the first region 35 f.

As mentioned above, the fluid-transfer article also includes a wick 37 f. In the arrangement shown in FIG. 71, the wick 37 f is flexible and U-shaped, with the arms of the U-shape extending through the second region 36 f into the first region 35 f. The wick 37 f is absorbent, so that its ends absorb aerosol precursor from the first region 35 f. For example, the wick 37 f may be of a cord material. The aerosol precursor will pass from the first region 35 f through and along the wick 37 f towards the base of the U-shape of the wick 37 f. As illustrated in FIG. 71, the base of the U-shape of the flexible wick 37 f is in contact with the heater 24 f at a heating region 38 f. Thus, when the heater 24 f is active, heat will be transferred from the heater 24 f to the wick 37 f, thereby heating the aerosol precursor which has been absorbed by the wick 37 f. The heating of the wick 37 f will release aerosol precursor from the wick 37 f, as a vapor and/or a mixture of vapor and aerosol.

The configuration of the wick 37 f is not limited to arrangement shown in FIG. 71 For example, it may be a relatively rigid body which forms an end for the region 35 f. The second region 36 f may then not be necessary. In such a case, the wick may be made of a porous polymer material, e.g., those referred to above as heat resistant polymeric wicking materials.

FIG. 71 also illustrates an opening 40 f in a further housing 33 f, which opening 40 f is in communication with the air-intake apertures 20 f. A further opening 40 f communicates with a duct 41 f within the housing 32 f, which duct 41 f communicates with the second end 18 f. The further housing 33 f may be integral with the housing 26 f containing the electrical energy supply 28 f.

There is thus a fluid-flow path for air (hereinafter referred to as an air-flow pathway) between openings 40 f and 39 f linking the apertures 20 f and the second end 18 f of the aerosol carrier. When the user sucks or inhales, air is drawn along the air-flow pathway, past a heating region 38 f of the heater 24 f.

One or more droplets of the aerosol precursor will be released from the wick 37 f as it is heated, to release vapor or a mixture of aerosol and vapor into the air flowing in the air-flow pathway between the openings 40 f, 39 f. The vapor or mixture passes, as the user sucks and inhales, to the second end 18 f.

FIG. 72 shows one embodiment of the heater 24 f in more detail. As illustrated, the heater 24 f has a heating region 38 f comprising alternating straight sections 42 f and U-shaped sections 43 f, so that heating region 38 f is convoluted. This enables good contact to be made between the heating region 38 f and the wick 37 f, whilst allowing for variations in their relative positions. Hence, when the housings 32 f and 33 f are joined, the contact between the wick 37 f and the heating region 38 f is not dependent on the precise positioning or orientation of the housings 32 f and 33 f

The heating region 38 f is supported on upright sections 25 f of the heater 24 f, which upright sections 25 f may extend from the coupling 30 f shown in FIG. 69.

The straight and U-shaped sections 42 f, 43 f of the heating region 38 f may be arranged so that, in the absence of deformation, they lie in a plane, whereby the heating region 38 f is flat prior to contact with the wick 37 f. That contact may then deform the heating region 38 f so that it becomes somewhat concave, thereby conforming at least partially to the shape of the wick 37 f. Alternatively, the heating region 38 f may be curved, either concave or convex, in the absence of deformation. For example, a convex arrangement, curved towards the wick 37 f, may assist in ensuring good contact between the wick 37 f and the heating region 38 f. It is possible for the whole of the heating region 38 f to be flexible, so both the straight sections 42 f and the U-shaped sections 43 f are flexible. Alternatively, however, only the U-shaped sections 43 f may be flexible, and the straight sections 42 f may be rigid, as this would still allow the heating region 38 f to conform to the wick 37 f. The opposite arrangement would also be possible, namely rigid U-shaped sections 43 f and flexible straight sections 42 f. In either case, it is desirable that the flexibility of the heating region 38 f of the heater 24 f is a resilient flexibility, both to allow the heating region 38 f to return to its original shape if the fluid-transfer article, and hence the wick, is removed from the rest of the apparatus, and also because the resilience will ensure that contact is not lost, e.g., due to impact on, or shaking of, the apparatus. The deformation of the heating region 38 f, due to its flexibility, will have the effect of increasing surface area contact between the heating region 38 f and the wick 37 f, which may improve the rate of vaporization of the aerosol precursor. This may be improved further it the wick 37 f is itself somewhat flexible.

The straight and U-shaped sections 42 f, 43 f of the heating region 38 f in FIG. 72 form a convoluted filament which is heated when current is passed therethrough. As mentioned above, the heater 24 f, and hence the heating region 38 f, is connected via the coupling 30 f to the electrical energy supply 28 f, so that the filament of the heating region 38 f will be heated due to that current when the apparatus is used. The filament forming the heating region 38 f has an electrical insulating coating thereon. The coating has a thickness not greater than 50 μm, with 20 μm being a preferred thickness. The coating will normally have a minimum resistance of 20Ω between any two points, although much higher resistances, such as greater than 1MΩ between any two points are preferred.

The coating may, for example, be of silicone sprayed onto the filament, or a potassium silicate paint painted or otherwise applied onto the filament. The filament itself may be any suitably conductive material, such as Nichrome. It is normally desirable for the electrically insulating coating to have as high a thermal conductance as possible. However, no further benefit is obtained once the thermal conductivity of the coating becomes greater than the thermal conductivity of the filament.

FIG. 73 illustrates another possible configuration of the heating region 38 f of the heater 24 f. In FIG. 7, the heating region 38 f comprises a substrate 44 f, which may be of insulating material, with a conductive filament 45 f supported thereon, preferably with a convoluted path. The filament 45 f ends in electrode tabs 46 f, which may be connected via the coupling 30 f to the electrical energy supply 28 f. The filament 45 f is again coated with an electrical insulating coating, corresponding to the electrical insulating coating described above with reference to FIG. 72.

In the arrangement of FIG. 73 the substrate 44 f may be relatively rigid. In such a case, it is desirable that the wick 37 f is then flexible, and preferably resilient, so that the wick will conform to the heating region 38 f where the two contact each other. For example, the wick 37 f may be of cord material. In the embodiments of FIGS. 72 and 73, the electrical insulation on the filament will reduce or eliminate any short circuit if the heater 24 f is deformed, since this would otherwise be a possible mode of failure.

The coating may also prevent or reduce aerosol precursor burning on to the surface of the heater, as the aerosol precursor passes from the wick 37 f to the heating region 38 f. This may prolong performance of the heater 24 f. As mentioned above, silicone or potassium silicate paint maybe used to coat the filament. The coating process may be by dipping or spraying of the filament. In the arrangement of FIG. 73 the insulating material maybe sprayed or coated onto the substrate 44 f, as well as onto the filament 45 f.

In the illustrative examples of FIG. 71, the first region 35 f of the fluid-transfer article 34 f is located at an “upstream” end of the fluid-transfer article 34 f and the flexible wick 37 f is located at a downstream” end of the fluid-transfer article 34 f. That is, aerosol precursor is wicked, or is drawn, from the “upstream” end of the fluid-transfer article 34 f to the “downstream” end of the fluid-transfer article 34 f (as denoted by arrow G in FIG. 71). In the arrangement of FIG. 71, the housing 32 f contains the first and first parts 35 f, 36 f of the fluid-transfer article, and also supports the wick 37 f. The heater 24 f is supported by the further housing 33 f which has the openings 40 f and 39 f therein, Housings 32 f and 33 f are separable, for example along the line H-H in FIG. 71 Thus, the housing 32 f and hence the fluid-transfer article 34 f may be removed from the rest of the structure, for example when the aerosol precursor therein has been depleted. The aerosol precursor may be re-filled, or the carrier 14 f replaced with another filled one. As mentioned above, the heating region 38 f may be flexible, and is preferably resilient. Then, when the carrier 14 f is in place, and the housing 32 f is in the position shown in FIG. 71 relative to the housing 33 f, the contact between the wick 37 f and the heating region 38 f will be resilient, so that the heating region 38 f is biased into contact with the wick 37 f to ensure good heat transfer to the wick 37 f.

In the arrangements shown in FIGS. 71 to 73, the apertures 40 f, 39 f are on opposite sides of the housing 32 f. FIGS. 74 and 75 show an alternative configuration, in which the fluid-transfer article is annular, and the first and first regions 35 f, 36 f are also annular. In FIGS. 74 and 75, the second region 36 f is illustrated in a position corresponding to that shown in FIG. 71, where it is spaced from the heating region 38 f of the heater 24 f. This enables the air flow in the apparatus to be illustrated. Thus, FIGS. 74 and 75 illustrate an aerosol carrier 14 f according to one or more possible arrangements in more detail. FIG. 74 is a cross-section side view illustration of the aerosol carrier 14 f and FIG. 75 is a perspective cross-section side view illustration of the aerosol carrier 14 f. As can be seen from FIGS. 74 and 75, the aerosol carrier 14 f is generally tubular in form. The aerosol carrier 14 f comprises housing 32 f, which defines the external walls of the aerosol carrier 14 f and which defines therein a chamber in which are disposed the fluid-transfer article 34 f (adjacent the first end 16 f of the aerosol carrier 14 f) and internal walls defining the fluid communication pathway 52 f. Fluid communication pathway 52 f defines a fluid pathway for an outgoing air stream from the channels 41 f to the second end 18 f of the aerosol carrier 14 f. In the examples illustrated in FIGS. 74 and 75, the fluid-transfer article 34 f is an annular shaped element located around the fluid communication pathway 52 f. A plurality of wicks 37 f may be provided around the fluid communication pathway 52 f, or there may be a single wick in the form of a toroid with a gap therein to form arms which pass through the second region 36 f of the fluid-transfer article and extend into the first part 35 f to receive aerosol precursor therefrom. Similarly, there may be a plurality of heaters 24 f around the fluid communication pathway 52 f, each being generally similar to either the arrangement shown in FIG. 72, or the arrangement shown in FIG. 73, or there may be single heater with a toroidal heating region 38 f.

In the walls of the housing 33 f, there are provided inlet apertures 53 f to provide a fluid communication pathway for an incoming air stream to reach the fluid-transfer article 34 f, and particularly the air-flow pathway defined past the heating region 38 f.

In the illustrated example of FIGS. 74 and 75, the aerosol carrier 14 f further comprises a filter element 54 f. The filter element 54 f is located across the fluid communication pathway 52 f such that an outgoing air stream passing through the fluid communication pathway 52 f passes through the filter element 54 f.

With reference to FIG. 75, when a user sucks on a mouthpiece of the apparatus (or on the second end 18 f of the aerosol carrier 14 f, if configured as a mouthpiece), air is drawn into the carrier through inlet apertures 53 f extending through walls in the housing 33 f. An incoming air stream 47 f from a first side of the aerosol carrier 14 f is directed to a first side of the second part 36 f of the fluid-transfer article 34 f (e.g., via a gas communication pathway within the housing of the carrier). An incoming air stream 48 f from a second side of the aerosol carrier 14 f is directed to a second side of the second part 36 f of the fluid-transfer article 34 f (e.g., via a gas communication pathway within the housing of the carrier). When the incoming air stream 47 f from the first side of the aerosol carrier 14 f reaches the first side of the second part 36 f, the incoming air stream 47 f from the first side of the aerosol carrier 14 f flows past the heating region 38 f. Likewise, when the incoming air stream 48 f from the second side of the aerosol carrier 14 f reaches the second side of the second part 36 f, the incoming air stream 48 f from the second side of the aerosol carrier 14 f flows past the heating region 38 f. The air streams from each side are denoted by dashed lines 49 f and 44 f in FIG. 75 As these air streams 49 f and 44 f flow, aerosol precursor in the flexible wick 37 f or on the heating region 38 f is entrained in air streams 49 f and 44 f.

In use, the heater 24 f of the apparatus 12 f raises a temperature of the wick 37 f, to a sufficient temperature to release, or liberate, captive substances (i.e., the aerosol precursor) to form a vapor and/or aerosol, which is drawn downstream. As the air streams 49 f and 44 f continue their passages, more released aerosol precursor is entrained within the air streams 49 f and 44 f. When the air streams 49 f and 44 f entrained with aerosol precursor meet at a mouth of the outlet fluid communication pathway 52 f, they enter the outlet fluid communication pathway 52 f and continue until they pass through filter element 54 f and exit outlet fluid communication pathway 52 f, either as a single outgoing air stream, or as separate outgoing air streams 51 f (as shown). The outgoing air streams 51 f are directed to an outlet, from where it can be inhaled by the user directly (if the second end 18 f of the aerosol capsule 14 f is configured as a mouthpiece), or via a mouthpiece. The outgoing air streams 51 f entrained with aerosol precursor are directed to the outlet (e.g., via a gas communication pathway within the housing of the carrier).

In FIGS. 74 and 75, the housing 32 f is separable from the housing 33 f, as in the arrangement of FIG. 71 This enables the carrier 14 f, hence the fluid-transfer article 34 f to be removed from the rest of the structure and a depleted aerosol precursor to be replaced.

In any of the embodiments described above the second region 36 f may have a thickness of less than 5 mm. In other embodiments it may have a thickness of: less than 3.5 mm, less than 3 mm, less than 2.5 mm, less than 2 mm, less than 1.9 mm, less than 1.8 mm, less than 1.7 mm, less than 1.6 mm, less than 1.5 mm, less than 1.4 mm, less than 1.3 mm, less than 1.2 mm, less than 1.1 mm, less than 1 mm, less than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less than 0.6 mm, less than 0.5 mm, less than 0.4 mm, less than 0.3 mm, less than 0.2 mm, or less than 0.1 mm. FIG. 76 is an exploded perspective view illustration of a kit-of-parts for assembling an aerosol delivery system 10 f.

As will be appreciated, in the arrangements described above, the fluid-transfer article 34 f is provided within a housing 32 f of the aerosol carrier 14 f. In such arrangements, the housing of the carrier 14 f serves to protect the aerosol precursor-containing fluid-transfer article 34 f, whilst also allowing the carrier 14 f to be handled by a user without his/her fingers coming into contact with the aerosol precursor liquid retained therein.

Seventh Mode: An aerosol-generation apparatus having a wick which receives aerosol precursor from a reservoir and which has an activation surface which makes abutting and unbonded contact with a heater.

Aspects and embodiments of the seventh mode of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference. In general outline, one or more embodiments in accordance with the seventh mode of the present disclosure may provide a system for aerosol delivery in which an aerosol carrier may be inserted into a receptacle (e.g., a “heating chamber”) of an apparatus for initiating and maintaining release of an aerosol from the aerosol carrier. Another end, or another end portion, of the aerosol carrier may protrude from the apparatus and can be inserted into the mouth of a user for the inhalation of aerosol released from the aerosol carrier cartridge during operation of the apparatus.

Hereinafter, and for convenience only, “system for aerosol delivery” shall be referred to as “aerosol delivery system”.

Referring now to FIG. 77, there is illustrated a perspective view of an aerosol delivery system 10 g comprising an aerosol generation apparatus 12 g operative to initiate and maintain release of aerosol from a fluid-transfer article in an aerosol carrier 14 g. In the arrangement of FIG. 77, the aerosol carrier 14 g is shown with a first end 16 g thereof and a portion of the length of the aerosol carrier 14 g located within a receptacle of the apparatus 12 g. A remaining portion of the aerosol carrier 14 g extends out of the receptacle. This remaining portion of the aerosol carrier 14 g, terminating at a second end 18 g of the aerosol carrier, is configured for insertion into a user's mouth. A vapor and/or aerosol is produced when a heater (not shown in FIG. 77) of the apparatus 12 g heats a fluid-transfer article in the aerosol carrier 14 g to release a vapor and/or an aerosol, and this can be delivered to the user, when the user sucks or inhales, via a fluid passage in communication with an outlet of the aerosol carrier 14 g from the fluid-transfer article to the second end 18 g.

The device 12 g also comprises air-intake apertures 20 g in the housing of the apparatus 12 g to provide a passage for air to be drawn into the interior of the apparatus 12 g (when the user sucks or inhales) for delivery to the first end 16 g of the aerosol carrier 14 g, so that the air can be drawn to the wick of a fluid-transfer article located within a housing of the aerosol carrier cartridge 14 g during use. Optionally, these apertures may be perforations in the housing of the apparatus 12 g.

A fluid-transfer article (not shown in FIG. 77 but described hereinafter with reference to FIGS. 81 to 84 is located within a housing of the aerosol carrier 14 g. The fluid-transfer article contains an aerosol precursor material, which may include at least one of: nicotine; a nicotine precursor material; a nicotine compound; and one or more flavorings. The fluid-transfer article is located within the housing of the aerosol carrier 14 g to allow air drawn into the aerosol carrier 14 g at, or proximal, the first end 16 g to flow to a wick of the fluid-transfer article. As air passes the wick of the fluid-transfer article, an aerosol may be entrained in the air stream from a substrate forming the fluid-transfer article, e.g., via diffusion from the substrate to the air stream and/or via vaporization of the aerosol precursor material and release from the fluid-transfer article under heating.

Part of the fluid-transfer article 33 g may comprise a porous material where pores of the porous material hold, contain, carry, or bear the aerosol precursor material. In particular, the porous material of the fluid-transfer article is a porous polymer material such as, for example, a sintered material. Particular examples of material suitable for the fluid-transfer article include: Polyetherimide (PEI); Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK); Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular Weight Polyethylene. Other suitable materials may comprise, for example, BioVyon™ (by Porvair Filtration Group Ltd) and materials available from Porex®. Further optionally, a substrate forming the fluid-transfer article may comprise Polypropylene (PP) or Polyethylene Terephthalate (PET). All such materials may be described as heat resistant polymeric wicking material in the context of the seventh mode of the present disclosure.

Alternatively, the fluid-transfer article 33 g may have an open reservoir for aerosol precursor, with a suitable seal to prevent leakage.

The aerosol carrier 14 g is removable from the apparatus 12 g so that it may be disposed of when expired. After removal of a used aerosol carrier 14 g, a replacement aerosol carrier 14 g can be inserted into the apparatus 12 g to replace the used aerosol carrier 14 g.

FIG. 78 is a cross-sectional side view illustration of a part of apparatus 12 g of the aerosol delivery system 10 g. The apparatus 12 g comprises a receptacle 22 g in which is located a portion of the aerosol carrier 14 g. In one or more optional arrangements, the receptacle 22 g may enclose the aerosol carrier 14 g. The apparatus 12 g also comprises a heater 24 g, which is in contact with part of a flexible wick of the fluid-transfer article (not shown in FIG. 78) of the aerosol carrier 14 g when an aerosol carrier 14 g is located within the receptacle 22 g. Air flows into the apparatus 12 g (in particular, into a closed end of the receptacle 22 g) via air-intake apertures 20 g. From the closed end of the receptacle 22 g, the air is drawn into the aerosol carrier 14 g (under the action of the user inhaling or sucking on the second end 18 g) and expelled at the second end 18 g. As the air flows into the aerosol carrier 14 g, it passes across the heating surface of the heater 24 g and around the flexible wick. Heat from the heater 24 g, which is in contact with the wick of the fluid-transfer article, causes vaporization of aerosol precursor material in the wick of the fluid-transfer article and an aerosol is created in the air flowing over the heating surface. Thus, through the application of heat, aerosol is released or liberated from the wick of the fluid-transfer article and is drawn from the material of the aerosol carrier unit by the air flowing across the heating surface of the heater and is transported in the air flow to the user via outlet conduits (not shown in FIG. 78) in the housing of the aerosol carrier 14 g to the second end 18 g. The direction of air flow is illustrated by arrows in FIG. 78.

To achieve release of the captive aerosol from the fluid-transfer article, the fluid-transfer article of the aerosol carrier 14 g, and in particular the flexible wick thereof, is heated by the heater 24 g. As a user sucks or inhales on second end 18 g of the aerosol carrier 14 g, the aerosol released from the wick of the fluid-transfer article and entrained in the air flowing across the activation surface of the fluid-transfer article is drawn through the outlet conduits (not shown) in the housing of the aerosol carrier 14 g towards the second end 18 g and onwards into the user's mouth.

Turning now to FIG. 79, a cross-sectional side view of the aerosol delivery system 10 g is schematically illustrated showing the features described above in relation to FIGS. 77 and 78 in more detail. As can be seen, apparatus 12 g comprises a housing 26 g, in which are located the receptacle 22 g and heater 24 g. The housing 26 g also contains control circuitry (not shown) operative by a user, or upon detection of air and/or vapor being drawn into the device 12 g through air-intake apertures 20 g, i.e., when the user sucks or inhales. Additionally, the housing 26 g comprises an electrical energy supply 28 g, for example a battery. Optionally, the battery comprises a rechargeable lithium-ion battery. The housing 26 g also comprises a coupling 30 g for electrically (and optionally mechanically) coupling the electrical energy supply 28 g to control circuitry (not shown) for powering and controlling operation of the heater 24 g.

Responsive to activation of the control circuitry of apparatus 12 g, the heater 24 g heats the wick of the fluid-transfer article (not shown in FIG. 79) of aerosol carrier 14 g. This heating process initiates (and, through continued operation, maintains) release of vapor and/or an aerosol from the activation surface of the fluid-transfer article. The vapor and/or aerosol formed as a result of the heating process is entrained into a stream of air being drawn across the heating surface of the heater (as the user sucks or inhales). The stream of air with the entrained vapor and/or aerosol passes through the aerosol carrier 14 g via outlet conduits (not shown) and exits the aerosol carrier 14 g at second end 18 g for delivery to the user. This process is briefly described above in relation to FIG. 78, where arrows schematically denote the flow of the air stream into the device 12 g and through the aerosol carrier 14 g, and the flow of the air stream with the entrained vapor and/or aerosol through the aerosol carrier cartridge 14 g.

FIGS. 80 to 82 schematically illustrate the aerosol carrier 14 g in more detail (and, in FIGS. 81 and 82, features within the receptacle in more detail). FIG. 80 illustrates an exterior of the aerosol carrier 14 g, FIG. 81 illustrates internal components of the aerosol carrier 14 g in one optional configuration, and FIG. 82 illustrates internal components of the aerosol carrier 14 g in another optional configuration.

FIG. 80 illustrates the exterior of the aerosol carrier 14 g, which comprises housing 31 g for housing said fluid-transfer article (not shown). The particular housing 31 g illustrated in FIG. 80 comprises a tubular member, which may be generally cylindrical in form, and which is configured to be received within the receptacle of the apparatus. First end 16 g of the aerosol carrier 14 g is for location to oppose the heater of the apparatus, and second end 18 g (and the region adjacent the second end 18 g) is configured for insertion into a user's mouth.

FIG. 81 illustrates some internal components of the aerosol carrier 14 g and of the heater 24 g of apparatus 12 g, in in one embodiment of the disclosure. As described above, the aerosol carrier 14 g comprises a fluid-transfer article 33 g including a flexible wick 36 g. Optionally, there may be a conduction element 37 g (as shown in FIG. 81), being part of the heater 24 g. In one or more other arrangements, the aerosol carrier 14 g is located within the receptacle of the apparatus such that the flexible wick 36 g of the fluid-transfer article is in contact with the heater 24 g of the apparatus and receives heat directly from the heater 24 g of the apparatus. The conduction element 37 g is disposed between the rest of the heater 24 g and the flexible wick 36 g of the fluid-transfer article. Heat may be transferred to the flexible wick 36 g via conduction through conduction element 37 g (i.e., application of heat to the activation surface is indirect).

Further components not shown in FIG. 81 comprise: an inlet conduit, via which air can be drawn into the aerosol carrier 14 g; an outlet conduit, via which an air stream entrained with aerosol can be drawn from the aerosol carrier 14 g; a filter element; and a reservoir for storing aerosol precursor material and for providing the aerosol precursor material to the fluid-transfer article 33 g.

In FIG. 81, the aerosol carrier is shown as comprising the fluid-transfer article 33 g located within housing 31 g. The fluid-transfer article 33 g comprises a first region 34 g holding an aerosol precursor. In one or more arrangements, the first region of 34 a of the fluid-transfer article 33 g comprises a reservoir for holding the aerosol precursor. The first region 34 g can be the sole reservoir of the aerosol carrier 14 g, or it can be arranged in fluid communication with a separate reservoir, where aerosol precursor is stored for supply to the first region 34 g. The material forming the first region of 34 a may comprise a porous structure, whose pore diameter size varies between one end of the first region 34 g and another end of the first region 34 g. The pore diameter size may decrease from a first end remote from heater 24 g (the upper end is as shown in the figure) to a second end. The change in pore size in the first region 34 g may be gradual rather than stepwise. This configuration of pores having a decreasing diameter size can provide a wicking effect, which can serve to draw fluid through the first region 34 g.

Particular examples of material suitable for the first region 34 g of the fluid-transfer article include: Polyetherimide (PEI); Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK); Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular Weight Polyethylene. Other suitable materials may comprise, for example, BioVyon™ (by Porvair Filtration Group Ltd) and materials available from Porex®. Further optionally, a substrate forming the fluid-transfer article may comprise Polypropylene (PP) or Polyethylene Terephthalate (PET).

Alternatively, the first region 34 g may be a simple liquid reservoir in the form of an empty tank for the receipt of liquid aerosol precursor, rather than porous material for holding the aerosol precursor.

The fluid-transfer article also comprises a second region 35 g, acting as a seal for the first region 34 g. This is particularly important if first region 34 g is an empty tank containing liquid. The second region 35 g thus prevents unwanted escape of aerosol precursor from the first region 34 g.

As mentioned above, the fluid-transfer article also includes flexible wick 36 g. In the arrangement shown in FIG. 81, the flexible wick 36 g is U-shaped, with the arms of the U-shape extending through the second region 35 g into the first region 34 g. The flexible wick 36 g is absorbent, so that its ends absorb aerosol precursor from the first region 34 g. That aerosol precursor will pass through and along the wick 36 g towards the base of the U-shape of the wick 36 g. As illustrated in FIG. 81, the base of the U-shape of the flexible wick 36 g is in contact with the conduction element 37 g. Thus, when the heater 24 g is active, heat will be transferred from the conduction element 37 g to the flexible wick 36 g, thereby heating the aerosol precursor which has been absorbed by the flexible wick 36 g. The heating will release aerosol precursor from the flexible wick 36 g, as a vapor and/or a mixture of vapor and aerosol.

FIG. 81 also illustrates an opening 38 g in a further housing 32 g, which opening 38 g is in communication with the air-intake apertures 20 g. A further opening 39 g communicates with a duct 40 g within the housing 31 g, which duct 40 g communicates with the second end 18 g. The further housing 32 g may be integral with the housing 26 g containing the electrical energy supply 28 g. There is thus a fluid-flow path for air (hereinafter referred to as an air-flow pathway) between openings 38 g and 39 g, linking the apertures 20 g and the second end 18 g of the aerosol carrier. When the user sucks or inhales, air is drawn along the air-flow pathway, along the surface of the conduction element 37 g, between the conduction element 37 g and the second region 35 g.

One or more droplets of the aerosol precursor will be released from the flexible wick 36 g as it is heated, to release vapor or a mixture of aerosol and vapor into the air flowing in the air-flow pathway between the openings 38 g, 39 g. The vapor or mixture passes, as the user sucks and inhales, to the second end 18 g.

As noted above, the conduction element 37 g may be absent in some arrangements.

The conduction element 37 g, if present, may comprise a thin film of thermally conductive material, such as, for example, a metal foil (for example, aluminum, brass, copper, gold, steel, silver, or an alloy comprising anyone of the foregoing together with thermally conductive plastics and/or ceramics). In the illustrative examples of FIG. 81, the first region 34 g of the fluid-transfer article 33 g is located at an “upstream” end of the fluid-transfer article 33 g and the flexible wick 36 g is located at a downstream” end of the fluid-transfer article 33 g. That is, aerosol precursor is wicked, or is drawn, from the “upstream” end of the fluid-transfer article 33 g to the “downstream” end of the fluid-transfer article 33 g (as denoted by arrow A in FIG. 81). In the arrangement of FIG. 81, the housing 31 g contains the first and first parts 34 g, 35 g of the fluid-transfer article, and also supports the flexible wick 36 g. The heater 24 g including the conduction element 37 g in FIG. 81 is supported by the further housing 32 g which has the openings 38 g and 39 g therein, Housings 31 g and 32 g are separable, for example along the line B-B in FIG. 81 Thus, the housing 31 g and hence the fluid-transfer article 33 g may be removed from the rest of the structure for example when the aerosol precursor therein has been depleted. The aerosol precursor may be re-filled, or the carrier 14 g replaced with another filled one. As mentioned above, the wick 36 g is flexible, and is preferably resilient. Then, when the carrier 14 g is in place, and the housing 31 g is in the position shown in FIG. 81 relative to the housing 32 g, the contact between the flexible wick 36 g and the conduction element 37 g will be resilient, so that the wick 36 g is biased into contact with the conduction element 37 g to ensure good heat transfer to the flexible wick 36 g.

As mentioned above, the conduction element 37 g need not be present. FIG. 82 illustrates an embodiment corresponding to that of FIG. 81, but without such a conduction element 37 g. The arrangement of FIG. 82 is otherwise similar to that of FIG. 81, and corresponding parts are indicated by the same reference numerals. In the arrangements shown in FIGS. 81 and 82, the apertures 38 g, 39 g are on opposite sides of the housing 31 g. FIGS. 83 and 84 show an alternative configuration, in which the fluid-transfer article is annular, and the first and first regions 34 g, 35 g are also annular. In FIGS. 83 and 84, the second region 35 g is illustrated in a position corresponding to that shown in FIGS. 81 and 82, where it is spaced from the conduction element 37 g. This enables the air flow in the apparatus to be illustrated. Thus, FIGS. 83 and 84 illustrate an aerosol carrier 14 g according to one or more possible arrangements in more detail. FIG. 83 is a cross-section side view illustration of the aerosol carrier 14 g and FIG. 84 is a perspective cross-section side view illustration of the aerosol carrier 14 g.

As can be seen from FIGS. 83 and 84, the aerosol carrier 14 g is generally tubular in form. The aerosol carrier 14 g comprises housing 31 g, which defines the external walls of the aerosol carrier 14 g and which defines therein a chamber in which are disposed the fluid-transfer article 33 g (adjacent the first end 16 g of the aerosol carrier 14 g) and internal walls defining the fluid communication pathway 48 g. Fluid communication pathway 48 g defines a fluid pathway for an outgoing air stream from the channels 40 g to the second end 18 g of the aerosol carrier 14 g. In the examples illustrated in FIGS. 83 and 84, the fluid-transfer article 33 g is an annular shaped element located around the fluid communication pathway 48 g. A plurality of wicks 36 g may be provided around the fluid communication pathway 48 g, or there may be a single wick in the form of a toroid with a gap therein to form arms which pass through the second region 35 g of the fluid-transfer article and extend into the first part 34 g to receive aerosol precursor therefrom.

In the walls of the housing 32 g, there are provided inlet apertures 50 g to provide a fluid communication pathway for an incoming air stream to reach the fluid-transfer article 33 g, and particularly the air-flow pathway defined across the conduction element 37 g (or across the heater 24 g).

In the illustrated example of FIGS. 83 and 84, the aerosol carrier 14 g further comprises a filter element 52 g. The filter element 52 g is located across the fluid communication pathway 48 g such that an outgoing air stream passing through the fluid communication pathway 48 g passes through the filter element 52 g.

With reference to FIG. 84, when a user sucks on a mouthpiece of the apparatus (or on the second end 18 g of the aerosol carrier 14 g, if configured as a mouthpiece), air is drawn into the carrier through inlet apertures 50 g extending through walls in the housing 32 g. An incoming air stream 41 g from a first side of the aerosol carrier 14 g is directed to a first side of the second part 35 g of the fluid-transfer article 33 g (e.g., via a gas communication pathway within the housing of the carrier). An incoming air stream 42 g from a second side of the aerosol carrier 14 g is directed to a second side of the second part 35 g of the fluid-transfer article 33 g (e.g., via a gas communication pathway within the housing of the carrier). When the incoming air stream 41 g from the first side of the aerosol carrier 14 g reaches the first side of the second part 35 g, the incoming air stream 41 g from the first side of the aerosol carrier 14 g flows along the conduction element 37 g (or along the heater 24 g). Likewise, when the incoming air stream 42 g from the second side of the aerosol carrier 14 g reaches the second side of the second part 35 g, the incoming air stream 42 g from the second side of the aerosol carrier 14 g flows along the conduction element 37 g (or along the heater 24 g). The air streams from each side are denoted by dashed lines 43 g and 44 g in FIG. 84 As these air streams 43 g and 44 g flow, aerosol precursor in the flexible wick 36 g or on the conduction element 37 g (or on the heater 24 g) is entrained in air streams 43 g and 44 g.

In use, the heater 24 g of the apparatus 12 g raises a temperature of the conduction element 37 g and hence the wick 36 g, to a sufficient temperature to release, or liberate, captive substances (i.e., the aerosol precursor) to form a vapor and/or aerosol, which is drawn downstream. As the air streams 43 g and 44 g continue their passages, more released aerosol precursor is entrained within the air streams 43 g and 44 g. When the air streams 43 g and 44 g entrained with aerosol precursor meet at a mouth of the outlet fluid communication pathway 48 g, they enter the outlet fluid communication pathway 48 g and continue until they pass through filter element 52 g and exit outlet fluid communication pathway 48 g, either as a single outgoing air stream, or as separate outgoing air streams 46 g (as shown). The outgoing air streams 46 g are directed to an outlet, from where it can be inhaled by the user directly (if the second end 18 g of the aerosol capsule 14 g is configured as a mouthpiece), or via a mouthpiece. The outgoing air streams 46 g entrained with aerosol precursor are directed to the outlet (e.g., via a gas communication pathway within the housing of the carrier).

In FIGS. 83 and 84, the housing 31 g is separable from the housing 32 g, as in the arrangements of FIGS. 81 and 82. This enables the carrier 14 g, hence the fluid-transfer article 33 g to be removed from the rest of the structure and a depleted aerosol precursor to be replaced.

In any of the embodiments described above the second region 35 g may have a thickness of less than 5 mm. In other embodiments it may have a thickness of: less than 3.5 mm, less than 3 mm, less than 2.5 mm, less than 2 mm, less than 1.9 mm, less than 1.8 mm, less than 1.7 mm, less than 1.6 mm, less than 1.5 mm, less than 1.4 mm, less than 1.3 mm, less than 1.2 mm, less than 1.1 mm, less than 1 mm, less than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less than 0.6 mm, less than 0.5 mm, less than 0.4 mm, less than 0.3 mm, less than 0.2 mm, or less than 0.1 mm.

FIG. 85 is an exploded perspective view illustration of a kit-of-parts for assembling an aerosol delivery system 10 g.

As will be appreciated, in the arrangements described above, the fluid-transfer article 33 g is provided within a housing 31 g of the aerosol carrier 14 g. In such arrangements, the housing of the carrier 14 g serves to protect the aerosol precursor-containing fluid-transfer article 33 g, whilst also allowing the carrier 14 g to be handled by a user without his/her fingers coming into contact with the aerosol precursor liquid retained therein.

Further aspects of the seventh mode of the present disclosure will now be described with reference to FIGS. 86 to 104. Referring to FIGS. 86 and 87, there is shown a smoking substitute system comprising a smoking substitute device 100. In this example, the substitute smoking system comprises a cartomizer 101 and a flavor pod 102. The cartomizer 101 may engage with the smoking substitute device 100 via a push-fit engagement, a screw-thread engagement, or a bayonet fit, for example. A cartomizer may also be referred to as a “pod”. The smoking substitute system may be an aerosol delivery device according to the seventh mode of the present disclosure.

The flavor pod 102 is configured to engage with the cartomizer 101 and thus with the substitute smoking device 100. The flavor pod 102 may engage with the cartomizer 101 via a push-fit engagement, a screw-thread engagement, or a bayonet fit, for example. FIG. 78 illustrates the cartomizer 101 engaged with the substitute smoking device 100, and the flavor pod 102 engaged with the cartomizer 101. As will be appreciated, in this example, the cartomizer 101 and the flavor pod 102 are distinct elements. Each of the cartomizer 101 and the flavor pod may be an aerosol delivery device.

As will be appreciated from the following description, the cartomizer 101 and the flavor pod 102 may alternatively be combined into a single component that implements the functionality of the cartomizer 101 and flavor pod 102. Such a single component may also be an aerosol delivery device according to the seventh mode of the present disclosure. In other examples, the cartomizer may be absent, with only a flavor pod 102 present, or vice versa.

A “consumable” component may mean that the component is intended to be used once until exhausted, and then disposed of as waste or returned to a manufacturer for reprocessing.

Referring to FIGS. 88 and 89, there is shown a smoking substitute system comprising a smoking substitute device 100 and a consumable 103. The consumable 103 combines the functionality of the cartomizer 101 and the flavor pod 102. In FIG. 88, the consumable 103 and the smoking substitute device 100 are shown separated from one another. In FIG. 89, the consumable 103 and the smoking substitute device 100 are engaged with each other.

Referring to FIG. 90, there is shown a consumable 103 engaged with a smoking substitute device 100 via a push-fit engagement. The consumable 103 may be considered to have two portions—a cartomizer portion 104 and a flavor pod portion 105, both of which are located within a single component (as in FIGS. 88 and 89).

The consumable 103 includes an upstream airflow inlet 106 and a downstream airflow outlet 107. In other examples a plurality of inlets and/or outlets are included. Between and fluidly connecting the inlet 106 and the outlet 107 there is an airflow passage 108. The outlet 107 is located at the mouthpiece 109 of the consumable 103 and is formed by a mouthpiece aperture.

As above, the consumable 103 includes a flavor pod portion 105. The flavor pod portion 105 is configured to generate a first (flavor) aerosol for output from the outlet 107 of the mouthpiece 109 of the consumable 103. The flavor pod portion 105 of the consumable 103 includes a member 115. The member 115 acts as a passive aerosol generator (i.e., an aerosol generator which does not use heat to form the aerosol, also referred to as a “first aerosol generator” in this example) and is formed of a porous material. The member 115 comprises a supporting portion 117, which is located inside a housing, and an aerosol generator portion 118, which is located in the airflow passage 108. In this example, the aerosol generator portion 118 is a porous nib. A first storage reservoir 116 (in this example a tank) for storing a first aerosol precursor (i.e., a flavor liquid) is fluidly connected to the member 115. The porous nature of the member 115 means that flavor liquid from the first storage 116 is drawn into the member 115. As the first aerosol precursor in the member 115 is depleted in use, further flavor liquid is drawn from the first storage reservoir 116 into the member 115 via a wicking action. As described above, the aerosol generator portion 118 is located within the airflow passage 108 through the consumable 103. The aerosol generator portion 118 therefore constricts or narrows the airflow passage 108. The aerosol generator portion 118 occupies some of the area of the airflow passage, resulting in constriction of the airflow passage 108. The airflow passage 108 is narrowest adjacent to the aerosol generator portion 118. Since the constriction results in increased air velocity and corresponding reduction in air pressure at the aerosol generator portion 118, the constriction is a Venturi aperture 119.

The cartomizer portion 104 of the consumable 103 includes a second storage reservoir 110 (in this example a tank) for storing a second aerosol precursor (i.e., e-liquid, which may contain nicotine). At one end of the second storage reservoir 110 is a wick support element 120, which supports a wick 111. As will be described in more detail later, aerosol precursor passes through one or more bores (not shown in FIG. 5) in the wick support element 120 to reach the wick 111. The surface of the wick furthest from the reservoir then acts as an activation surface from which aerosol precursor will be released in the form of a vapor, or a mixture of vapor and aerosol.

A heater 112 is a configured to heat the wick 111. The heater 112 may be in the form of one or more resistive heating filaments that abut the wick 111. The wick 111, the heater 112 and the e-liquid storage reservoir 110 together act as an active aerosol generator (i.e., an aerosol generator which uses heat to form the aerosol, referred to as a “second aerosol generator” in this example). The second storage reservoir 110, the wick support element, and the wick 111 form a fluid-transfer article, as they transfer aerosol precursor to the activation surface to be heated by the heater 112.

The heater 112 is supported in the smoking substitute device 100 by a heater support element 130.

15 There may be one or more passages (not shown in FIG. 90) through the heater support element 130 to allow air to reach the activation surface of the wick 111 from an inlet (again not shown in FIG. 90) of the smoking substitute device.

The smoking substitute device 100 includes an electrical power source (not shown), for example a battery. That battery is then connected via suitable electrical connections to the heater 112. The heater 112, the battery, and other components of the smoking substitute system device 100 form a non-consumable part of the device from which the consumable may be connected and disconnected.

In the arrangement of the smoking substitute device 100 of FIG. 90, and in the arrangements to be described later, the consumable 103 is separable from the rest of the smoking substitute device 100. This allows the consumable 103 to be replaced, or possibly refilled, when the first and/or second aerosol precursor have been consumed by the user. Since the consumable 103 includes the wick 111 and the wick support element 120, these components will be removed when the consumable 103 is separated from the rest of the smoking substitute device 100. The heater 112, on the other hand, will remain when the consumable 103 is removed, so that it is non-consumable.

In use, a user draws (or “sucks”, or “pulls”) on the mouthpiece 109 of the consumable 103, which causes a drop in air pressure at the outlet 107, thereby generating air flow through the inlet, through the passages in the heater support element 130, past the activation surface of the wick 111, along the airflow passage 108, out of the outlet 107 and into the user's mouth.

When the heater 112 is activated (by passing an electric current through one or more heating filaments in response to the user drawing on the mouthpiece 109) the e-liquid (aerosol precursor) located in the wick 111 at the activation surface adjacent to the or each heating filament is heated and vaporized to form a vapor. The vapor condenses to form the second aerosol within the airflow passage 108. Accordingly, the second aerosol is entrained in an airflow along the airflow flow passage 108 to the outlet 107 and ultimately out from the mouthpiece 109 for inhalation by the user when the user draws on the mouthpiece 109.

The substitute smoking device 100 supplies electrical current to the heating filament or filaments of the heater 112 and the heating filament or filaments heats up. As described, the heating of the heating filament or filaments causes vaporization of the e-liquid in the wick 111 to form the second aerosol.

As the air flows up through the airflow passage 108, it encounters the aerosol generator portion 118. The constriction of the airflow passage 108 caused by the aerosol generator portion 118 results in an increase in air velocity and corresponding decrease in air pressure in the airflow in the vicinity of the porous surface 118 of the aerosol generator portion 115. The corresponding low-pressure region causes the generation of the first (flavor) aerosol from the porous surface 118 of the aerosol generator portion 118. The first (flavor) aerosol is entrained into the airflow and ultimately is output from the outlet 107 of the consumable 103 and thus from the mouthpiece 109 into the user's mouth.

The first aerosol may be sized to inhibit pulmonary penetration. The first aerosol may be formed of particles with a mass median aerodynamic diameter that is greater than or equal to 15 microns, in particular, greater than 30 microns, more particularly greater than 50 microns, yet more particularly greater than 60 microns, and even more particularly greater than 70 microns.

The first aerosol may be sized for transmission within at least one of a mammalian oral cavity and a mammalian nasal cavity. The first aerosol may be formed by particles having a maximum mass median aerodynamic diameter that is less than 300 microns, in particular less than 200 microns, yet more particularly less than 100 microns. Such a range of mass median aerodynamic diameter will produce aerosols which are sufficiently small to be entrained in an airflow caused by a user drawing air through the flavor element and to enter and extend through the oral and or nasal cavity to activate the taste and/or olfactory receptors.

The second aerosol generated may be sized for pulmonary penetration (i.e., to deliver an active ingredient such as nicotine to the user's lungs). The second aerosol may be formed of particles having a mass median aerodynamic diameter of less than or equal to 10 microns, preferably less than 8 microns, more preferably less than 5 microns, yet more preferably less than 1 micron. Such sized aerosols tend to penetrate into a human user's pulmonary system, with smaller aerosols generally penetrating the lungs more easily. The second aerosol may also be referred to as a vapor. The size of aerosol formed without heating is typically smaller than that formed by condensation of a vapor.

As a brief aside, it will be appreciated that the mass median aerodynamic diameter is a statistical measurement of the size of the particles/droplets in an aerosol. That is, the mass median aerodynamic diameter quantifies the size of the droplets that together form the aerosol. The mass median aerodynamic diameter may be defined as the diameter at which 50% of the particles/droplets by mass in the aerosol are larger than the mass median aerodynamic diameter and 50% of the particles/droplets by mass in the aerosol are smaller than the mass median aerodynamic diameter. The “size of the aerosol”, as may be used herein, refers to the size of the particles/droplets that are comprised in the particular aerosol.

Referring to FIG. 82, there is shown a flavor pod portion 202 of a consumable, the consumable providing an aerosol delivery device in accordance with the disclosure. The consumable further comprises a cartomizer portion (not shown in FIG. 82) having all of the features of the cartomizer portion 104 described above with respect to FIG. 81.

The flavor pod portion 202 comprises an upstream (i.e., upstream with respect to flow of air in use) inlet 204 and a downstream (i.e., downstream with respect to flow of air in use) outlet 206. Between and fluidly connecting the inlet 204 and the outlet 206 the flavor pod portion 204 comprises an airflow passage 208. The airflow passage 208 comprises a first airflow branch 210 and a second airflow branch 212, each of the first airflow branch 210 and the second airflow branch 212 fluidly connecting the inlet 204 and the outlet 206. In other examples the airflow passage 208 may have an annular shape. The outlet 206 is located at the mouthpiece 209 of the consumable 103 and is also referred to as a mouthpiece aperture 206. The flavor pod portion 202 comprises a storage 214, which stores a first aerosol precursor. The storage 214 comprises a reservoir 216 located within a chamber 218. The reservoir 216 is formed of a first porous material.

The flavor pod portion 202 comprises a member 220, which comprises an aerosol generator portion 222 and a supporting portion 223. The aerosol generator portion 222 is located at a downstream end (an upper end in FIG. 82) of the member 220, while the supporting portion 223 makes up the rest of the member 220. The supporting portion 223 is elongate and substantially cylindrical. The aerosol generator portion 222 is bulb-shaped and comprises a portion which is wider than the supporting portion 223. The aerosol generator portion 222 tapers to a tip at a downstream end of the aerosol generator portion 222.

The member 220 extends into and through the storage 214. The member 220 is in contact with the reservoir 216. More specifically, the supporting portion 223 extends into and through the storage 204 and is in contact with the reservoir 216. The member 220 is located in a substantially central position within the reservoir 216 and is substantially parallel to a central axis of the consumable. The member 220 is formed of a second porous material.

The first and second airflow branches 210, 212 are located on opposite sides of the member 220. Additionally, the first and second airflow branches 210, 212 are located on opposite sides of the reservoir 216. The first and second airflow branches 210, 212 branch in a radial outward direction (with respect to the central axis of the consumable 200) downstream of the inlet 204 to reach the opposite sides of the reservoir 216.

The aerosol generator portion 222 is located in the airflow passage 208 downstream of the first and second airflow branches 210, 212. The first and second airflow branches 210, 212 turn in a radially inward direction to merge at the member 220, at a point upstream of the aerosol generator portion 222.

The aerosol generator portion 222 is located in a narrowing section 224 of the airflow passage 208. The narrowing section 224 is downstream of the point at which the first and second airflow branches 210 212 merge, but upstream of the mouthpiece aperture 207. The mouthpiece aperture 207 flares outwardly in the downstream direction, such that a width of the mouthpiece aperture 207 increases in the downstream direction.

In use, when a user draws on the mouthpiece 209, air flow is generated through the air flow passage 208. Air (comprising the second aerosol from the cartomizer portion as explained above with respect to FIG. 81) flows through the inlet 204 before the air flow splits to flow through the first and second airflow branches 210, 212. Further downstream, the first and second airflow branches 210, 212 provide inward airflow towards the member 220 and the aerosol generator portion 222.

As air flows past the aerosol generator portion in the narrowing section 224, the velocity of the air increases, resulting in a drop in air pressure. This means that the air picks up the first aerosol precursor from the aerosol generator portion 222 to form the first aerosol. The first aerosol has the particle size and other properties described above with respect to FIG. 81 As the first aerosol precursor is picked up by the air, the member 220 transfers further first aerosol precursor from the storage 214 to the aerosol generator portion 222. More specifically, the member 220 wicks the first aerosol precursor from the storage 214 to the aerosol generator portion 223.

In other examples, the storage 214 comprises a tank containing the first aerosol precursor as free liquid, rather than the reservoir 216 and the chamber 218. In such examples, the member 220 still extends into the tank to transfer first aerosol precursor from the tank to the aerosol generator portion 223.

Further arrangements of the seventh mode of the present disclosure will now be described, which arrangements incorporate one or more features of the aspects of the seventh mode of the present disclosure. In the subsequent arrangements, the smoking substitute device 100 includes a consumable 103 in the form of a cartomizer but does not include a flavor pod. However, the smoking substitute device 100 of the subsequent arrangements may be modified to incorporate a flavor pod in a way similar to the arrangement of FIGS. 90 and 91.

As mentioned above, the wick 111 is supported by a wick support element 120. FIG. 92 illustrates an arrangement of a smoking substitute system in which these components are illustrated in more detail, and in an exploded view. The wick support element 120 is mounted at an end of the second storage reservoir 111 and has bores 122 therethrough to allow aerosol precursor in the second storage reservoir 110 to pass to the wick 110. These bores may be sized so that aerosol precursor may flow therethrough in a non-capillary manner. Although, two bores 122 are visible in FIG. 92, there may be more arranged around the wick support element 120.

In the arrangement of FIG. 92, the wick support element 120 is made of a resilient material, such as rubber, and thus may deform when force is applied thereto. In particular, when the consumable 103 is mounted on the main body 100, the wick 111 is brought into contact with the heater 112 and is held thereto by the resilience of the wick support element 120. The wick support element 120 may be sized so that it deforms slightly when the wick 111 is in contact with the heater 112, so as to provide a biasing force to urge the wick 111 into firm contact with the heater 112.

The wick 111 has an opening 124 at its center, which is aligned with a passageway 126 through the wick support element 122. The passageway 126 communicates with the air-flow passage 108 shown in FIG. 81 so that air, together with vapor or a mixture of vapor and aerosol, will pass to the user. The surface of the wick 111 closest to the heater 112 acts as an activation surface for the aerosol precursor and, as the wick 111 is heated by the heater 112, aerosol precursor is released from the activation surface in the form of vapor or a mixture of vapor and aerosol, it can then pass through the opening 124 and the passageway 126 into the air-flow passage 108. As illustrated in FIG. 92, the heater 112 is mounted on a heater support element 130, which may act as an end wall of a battery housing, and which may itself be supported by a support wall 132. The casing of the main body 100 (not shown in FIG. 92) will enclose the support wall 132 and parts of the heater support element 130. In order for air to flow from the activation surface of the wick 111 through the opening 124 and into the passage 126, air must first reach the activation surface of the wick 111. The support wall 132 may thus have a bore 134 therethrough, which communicates with passages (not shown in FIG. 92) through the heater support element 130. FIG. 93 illustrates these passages 136 and shows that they open immediately adjacent the heater 112 and hence adjacent the activation surface of the wick 111. The casing of the main body 100 may be provided with an inlet at a suitable location, to allow air to reach the bore 134, and hence to flow to the passages 136 in the heater support element 130. Hence, when the user draws on the mouthpiece 109 of the consumable 103, air is drawn into the casing of the main body 100 through the bore 134 and the passages 136 to reach the activation surface of the wick 111 adjacent the heater 112. That air then passes, together with vapor or mixture of aerosol and vapor generated by heating of the aerosol precursor by the heater 112, through the opening 124 in the wick 111 to the passage 126, and hence to the air-flow passage 108, and then to user, as has previously been described.

Note that in the arrangement of FIGS. 92 and 93, the heater 112 will need to be connected to a power source, such as a battery, and there may then need to be additional bores (not shown in FIGS. 92 and 93) through the heater support element 130 and the support wall 132 to allow electrical leads to pass therethrough. FIG. 94 illustrates another arrangement of a smoking substitute system, in which the consumable has a single reservoir for aerosol precursor which corresponds to the second storage reservoir 110 in the embodiment of FIG. 90 In this arrangement, the consumable does not have a flavor pod portion. For simplicity, parts corresponding to those of FIGS. 90 to 93 are indicated by the same reference numerals. Note that in FIG. 94, the support wall 132 has multiple bores 134 therethrough, aligned with the passages 136 in the heater support element 130.

FIG. 94 also shows the casings of the device. In particular, there is a casing 300 (the “first” casing), being a casing of the consumable 103. That casing contains the reservoir 110 for aerosol precursor, and also supports the wick support element 120 and the wick 111. A tube 302 within that first casing 300 forms a bounding wall of the air-flow passage 108, and the mouthpiece 109 is formed at an end of the first casing 300. The main device 100 also has a casing 310 (the “second” casing) on which are mounted the support wall 132 and the heater support element 130. There is a space 312 within the second casing 310 for a battery and other electronic components used to power the heater 112, and the second casing 310 may also have an inlet 314 to allow air to enter the space 312 and hence pass to the bores 134 and the passages 136 to enable it to reach the activation surface of the wick 110.

FIG. 94 also shows electrical leads 138 which extend through the support wall 132 and the heater support element 130 to enable the heater 112 to be connected to a battery in space 312. Small bores may be formed in the heater support element 130 and the support wall 132 through which the leads 138 may pass. The first and second casings 300, 310 are separable and held together by a “click” engagement 316. When the two casings 300,310. are interconnected, as shown in FIG. 9, the wick 111 is forced into contact with the heater 112 by the resilience of the wick support element 120, so that good heating of the activation surface of the wick 111 will occur when the heater 112 is active. The separability of the two casing 300, 310 allows the consumable 103 to be removed from the main body 100, and replaced, e.g., when the aerosol precursor in the reservoir 110 is exhausted.

FIG. 95 shows a perspective view of the consumable 103 in FIG. 94, with the part of the first casing 300 removed so that the wick 111 and the wick support element 120 are clearly visible. It can be seen from FIG. 95 that the wick 111 is flat and so has a planar activation surface (the exposed surface of the wick 111 in FIG. 95). FIG. 95 also shows clearly the opening 124 in the wick 111, which allows communication with the passageway 126 through the wick support element 120. The wick support element 120 in this embodiment, and in some other embodiments, is preferably made of rubber material. In a similar way, the wick 111 is preferably made of silica material, which material is suitably porous to allow the aerosol precursor to pass therethrough. Alternatively, the wick may be of fibrous material, woven material, or porous ceramic material. FIGS. 96 and 97 illustrate two alternative configurations of a heater support element 130 which may be used in the seventh mode of the present disclosure. They differ in the shape of the mouth of the passage 136 through the heater support element 130 which allows air to pass through the heater support element from, e.g., the interior of the casing of the main body 100 to the vicinity of the heater 112 and the activation surface of the wick 111. Note that, in FIGS. 96 and 97, the heater itself is not shown and there is a single passage 134 through the heater support element 132. In each of the alternative configurations, the heater support element 130 is preferably made of resilient material, which must also be suitable to resist the heat generated by the heater 112.

In FIG. 96, the heater support element 130 comprises a body part 500 which has a peripheral seal surface 502 which seals to the casing 310 (not shown in FIG. 96). The seal between the seal surface 502 and the casing 310 needs to be sufficiently strong to prevent, or at least significantly resist, movement of the heater support element 130 in the casing 310, particularly when the consumable 103 is removed from the main body 100.

A projecting part 504 projects from the body part 500, terminating in a flat heater support face 506. The periphery of the projecting part 504 seals to the casing 300 of the consumable 103, and for this purpose may have ribs 508 on its side surface. However, unlike the sealing of the seal surface 502 to the casing 310 of the main body 100, the sealing of the projecting part 504 to the casing 300 of the consumable 103 needs to allow the consumable 103 to be removed to allow another consumable 103 to be mounted thereon without too much resistance. Nevertheless, the sealing must be sufficiently good to limit leakage of any aerosol precursor which has passed through the wick 111 but has not been vaporized by the heater 112. As in the arrangement of FIG. 94, the passage 136 passes through the heater support element 130 to enable air to pass towards the heater 112 and the wick 111. In the heater support element 130 shown in FIG. 96, the passage 136 terminates in a splayed or funneled mouth 510, which opens into a slot 512 in the heater support surface 506, so that air which has passed through the bore 136 can expand in the funneled mouth 510 before reaching the heater 112.

FIG. 96 also shows bores 514 through which pass leads from the heater 112, which leads will provide electrical connection to the battery. The heater support element 130 shown in FIG. 96 is resilient and is preferably made of silicone material, with provision to resist high temperatures which may be generated by the heater 112. For example, the material known as Polygraft HT-3120 silicone, which is a two-part mix, may be a suitable material from which the heater support element 132 may be made. The configuration shown in FIG. 96 will normally be made by molding the silicone material in a suitable mold. FIG. 97 illustrates an alternative heater support element 130. It is generally similar to the heater support element 130 shown in FIG. 96 and the same reference numerals indicate corresponding parts. It may be made of the same materials as the heater support element 130 of FIG. 96 The heater support element 130 of FIG. 97 differs from that of FIG. 96 in that the passage 136 opens directly into the channel 512 in the heater support surface 506. There is thus a flat face 516 at the bottom of the channel 516, rather than the funnel mouth 510 shown in FIG. 96.

FIG. 98 shows a heater that may be used with the heater support element 130 shown in FIG. 96 or FIG. 97 The heater comprises a heater filament 520 which is generally flat and rests on the heater support face 506 of the heater support element 130. For this reason, the filament 520 is not straight but meanders in its plane. FIG. 98 also shows the leads 138 which extend through the bores 514 of the heater support 130 shown in FIG. 96 or FIG. 97, to enable the heater 112 to be connected to a battery.

FIG. 99 illustrates an arrangement of a smoking substitute system which incorporates the heater support element 132 of FIG. 96, and also the heater 112 of FIG. 98 The arrangement of FIG. 99 is generally similar to that of FIG. 94, and corresponding parts are indicated by the same reference numerals. As mentioned previously, when the heater support element 132 of FIG. 96 is used, there is only a single bore 136 therein for air, hence there is only a single bore 134 in the support 132 in the main body 100. The bore 136 extends to the funneled mouth 510 which opens into the slot 512 directly below the heater 112. Note that the leads 138 of the heater 112 are not visible in FIG. 99.

FIG. 99 illustrates how the seal surface 502 of the main body 500 seals to the second casing 310, and the projecting part 504 seals to the first casing 300. This sealing is illustrated in more detail in the enlarged view of FIG. 100 In particular, the first casing 300 of the consumable 103 extends sufficiently far within the second casing 310 of the main body 100 so as to contact the projecting part 504 of the heater support element 130 at a sealing interface 518. Similarly, the main body 500 of the heater support element 130 seals at a sealing interface 520 with the casing 310 of the main body 100. As mentioned previously, the degrees of sealing at these two sealing interfaces 518 and 520 are preferably different, since the heater support element 130 does not normally release from the second casing 310 but must release from the first casing 300 when the consumable 103 is removed. FIG. 100 also shows how the funneled mouth 510 of the passage 136 opens within the heater support element 130 towards the heater 112 and the wick 111. This causes the air flow from the passage 136 to expand, as illustrated by the arrows 522, so that there is a good air flow where the heater 112 meets the wick 111, to entrain vapor therein prior to flow to the passage 126 in the wick support element 120.

With the arrangement shown in FIG. 100, as in the other arrangements, the sealing between the first casing 300 and the heater support element 130 at the sealing interface 518 prevents any leakage of aerosol precursor which has come from the wick 111 and has not been vaporized by the heater 112. Hence, when the consumable 103 is fitted in place on the main body 100, the only escape route for the aerosol precursor is via the air flow passage 108 and the mouthpiece 109. This helps to ensure efficient consumption of the aerosol precursor. The arrangement of FIG. 99 also differs from the arrangement of FIG. 94 (and also that of FIG. 100), in that the wick 111 extends across the whole of the end face of the wick support element 120, as in the arrangement of FIG. 95 As before, the wick 111 has an opening 124 therein to allow air to pass through the wick 111 and into the passage 126, and hence through the air-flow passage 108 so that it can reach the outlet 109 and thus pass to the user. FIG. 101 shows another arrangement of a smoking substitute system, which is generally similar to that of the embodiment of FIGS. 94 and 95 and corresponding parts are indicated by the same reference numerals. In the embodiment of FIG. 25, however, there is no heater support element 130, and instead the heater 112 is a coil or other filament held within the second casing 310, which has a space 400 adjacent thereto. The space 400 communicates with inlets (not shown in FIG. 101) which allow air to enter the casing 310 and pass to the activation surface of the wick 111. Again, the wick 111 is forced into contact with the heater 112 by the resilience of the wick support element 120. In this arrangement, the flow of air to the activation surface is not restricted by the size of the passage or passages through the heater support element 130. In this arrangement the heater 112 needs to be sufficiently stiff that it is not deformed when the wick 111 is urged into contact therewith by the resilient wick support element 120.

In the arrangements of the smoking substitute system described above, the wick support element 120 is a separate element from the first casing 300 of the consumable 103. FIG. 102 illustrates an alternative arrangement, in which the wick support element is integral with part of the first casing 300.

In the arrangement of FIG. 102, parts which correspond to arrangements described previously are indicated by the same reference numerals. Note that, in FIG. 102, the main body 100 is not shown. It may be the same as in the other arrangements of a smoking substitute system described previously.

In the arrangement of FIG. 102, the first casing 300 has a lower part 301 and an upper part 303. The mouthpiece 109 is in the upper part 303, and the tube 302 is also integral with that upper part 303.

The lower part 301 has an upper rim which meets a lower rim of the upper part 303 at a sealing surface 600 and has an internal flange 602 adjacent its lower end. The internal flange 602 corresponds to the wick support element 120 of the arrangements previously described. The internal flange 602 has a central bore forming passage 126, which passage is aligned with the passage 108 within the tube 302. The end of the tube 302 furthest from the mouthpiece 109 engages the flange 602 and is sealed thereto.

The interiors of the upper and lower parts 303 and 301 of the casing 300 are hollow and form the reservoir 110. There are bores 122 in the flange 602 to allow the reservoir 110 to communicate with the wick 111, in the same way as the bores 122 in the earlier arrangements described previously. Thus, aerosol precursor in the reservoir 110 may pass through the bores 122 to saturate the wick 111, and then be heated by the heater 112 (not visible in FIG. 102). The arrangement of FIG. 102 prevents any leakage of aerosol precursor between the wick support element 120 and the casing 300. Whilst there could be leakage between the upper and lower parts 303, 301 of the casing 300, this can be prevented by suitable configuration of the sealing interface 600. However, if the sealing of the reservoir 110 is too good, air may not be able to enter it to replace aerosol precursor which has been consumed.

Therefore, FIG. 102 shows that there may be at least one additional bore 604 in the flange 602, to allow passage of air to the reservoir 110 from outside the first casing. The or each additional bore 604 needs to be sufficiently small that it will not allow a significant amount of aerosol precursor to pass therethrough. For example, the or each additional bore 604 may be, e.g., 0.2 to 0.5 mm in diameter, more preferably 0.32 to 0.5 mm, even more preferably 0.32 to 0.4 mm. If the flange has a thickness of, e.g., 0.5 to 5 mm, preferably 1 to 5 mm, aerosol precursor should not be able to escape reservoir 110 through the or each additional bore 604. In general, the thicker the flange 602, the greater the possible diameter of the or each additional bore 604 may be, without it allowing aerosol precursor to flow therethrough. A thin flange 602 (which thinness may be desirable for manufacture) will thus need the diameter of the or each additional bore to be small.

The upper and lower parts 301, 303 of the casing 300 may be separable to allow for refiling of the reservoir 110 once the aerosol precursor wherein has been consumed. In such an arrangement, the sealing at the sealing surface 640 needs to be sufficiently good to prevent leakage of aerosol precursor therethrough when the smoking substitute system is in use. Alternatively, the seal at the sealing surface 600 may be a permanent one, with the upper and lower parts 301 and 303 if the casing bonded together. In such an arrangement, the reservoir 110 may not be refillable, and the consumable 103 would need to be replaced once the aerosol precursor in the reservoir 110 had been consumed.

In the arrangements described previously, the bores 122 in the wick support element 120 (or in the flange 602 in the case of FIG. 102) were described as being sized so that aerosol precursor may flow therethrough in a non-capillary manner. In an alternative, applicable to all the arrangements described previously, the bores 122 may be capillary ducts (hereinafter referred to as capillary bores) which allow aerosol precursor to flow therethrough in a capillary manner. The capillary bores allow the flow of aerosol precursor to the wick 111, in a controlled manner, so that there is less chance of there being excess aerosol precursor at the wick 111. In general, the capillary bores may have a diameter range of 0.3 mm to 2 mm, as a diameter of less than 0.3 mm will generally not allow sufficient aerosol precursor to pass to the wick 111. Preferably, the diameter is at least 0.5 mm, preferably 0.8 to 1.5 mm, and more preferably 1 mm or 1.3 mm. In practice, the diameter of the capillary bores may be affected by the thickness of the wick support element 120, which can have a thickness of, e.g., 0.5 mm to 5 mm, more preferably 1 to 5 mm, such as 4 mm, 3 mm, 2 mm and 1 mm. In general, the width of the capillary bores will need to be greater with greater thickness of the wick support element 120.

In the arrangements of FIGS. 91 to 101, the wick support element 120 is made of resilient material such as rubber. In the arrangement of FIG. 102 on the other hand, the support for the wick 111 is rigid, because it was formed by the internal flange 602 which was integral with, and therefore made of the same material as, the casing 300. FIGS. 103 and 104 then illustrate another arrangement in which the wick is supported by a rigid element. Unlike the arrangement of FIG. 102, however, in the arrangement of FIGS. 103 and 104, that rigid element is a separate wick support element 720. In FIGS. 103 and 104, parts which correspond to parts of earlier arrangements are indicated by the same reference numerals. Moreover, as in FIG. 102, only the consumable 103 is illustrated. The main part 100 may be the same as in earlier arrangements. In particular, in the arrangements of FIGS. 103 and 104, the rigid wick support element 720 is formed at an end of the reservoir 110, within the first casing 300. Bores 122 through the wick support element 720 allow aerosol precursor from the reservoir 110 to pass to wick 111. Whilst the bores 122 may be non-capillary bores, they are preferably capillary bores. The diameter of the capillary bores may be as previously described, as may the thickness of the wick support element 720. Although not illustrated in FIGS. 103 and 104, there may need to be an additional bore or bores in the wick support element 720 to allow passage of air to the reservoir 110, corresponding to the at least one additional bore 604 in FIG. 102.

In order to prevent escape of liquid from the reservoir, the wick support element 720 is preferably sealed to the first casing 300 by seals 610. For example, the seals 610 may be O-ring seals extending around the wick support element 120. The seals can be seen clearly in FIG. 104, as can the opening 124 in the wick 111, which leads to the passage 126 through the wick support element 720 to the air-flow passage 108. The wick support element 720 also needs to be sealed to the tube 302, to prevent escape of aerosol precursor from the reservoir 110. To achieve this, the wick support element 720 may have an upstanding ring 612, which then seals (e.g., by O-rings and/or an interference fit) to the tube 302. Grooves for those O-rings are illustrated in FIG. 104 Another possibility is for the tube 302 to be integral with the wick support element 720, with the end of the tube 302 being sealed to the casing 300 adjacent the mouthpiece 109. The rigidity of the wick support element 720 and the tube 302 means that the positioning of the wick support element 720 on the tube 302 and the positioning of the tube 302 relative to the casing 300 may be determined to good precision. This ensures that the wick 111 is accurately positioned relative to the casing 300, and hence accurately positioned relative to the casing 310 and the heater 112.

In the arrangement of FIGS. 103 and 104, the wick support element 720 may be made of the same material as the casing 300 (and the casing 310) such as being made from molded polypropylene plastics material. Other suitable materials to form the wick support element 720 include ABS and PEAK materials. The seals 610 may be O-rings of, e.g., rubber material or silicone seals co-molded with the wick support element 720, but preferably are nitrile or thermoplastic polymer O-ring seals. The molding of the wick support element 720 and the first and second casings 300, 310 simplifies manufacture. Because the wick support element 720 is rigid in the arrangement of FIGS. 103 and 104, it may be thinner than the resilient wick support elements 120 described with reference to, e.g., FIGS. 90 to 101. Thus, it may then be possible to have a wick support element 720 with a thickness of, e.g., 0.5 to 2 mm, preferably 1 mm, allowing the bores 122 to have a small diameter, and still provide a capillary effect. The same is true in the arrangement of FIG. 102 Thus, at least in the arrangements of FIGS. 102 to 104, the bores 122 may have a diameter of 0.3 mm to 2 mm, most preferably 0.5 mm. If one or more additional bores are provided, corresponding to the additional bores 604 in the arrangement of FIG. 103, to allow air to enter the reservoir volume to replace aerosol precursor which has passed to the wick 111, those additional bores will have small diameters, due to the reduced thickness of the wick support element 720, so, e.g., less than 0.3 mm. The diameter of the additional bores will always be less than the diameter of the capillary bores. It should be noted that, even in the arrangements of FIGS. 90 to 101, it may be possible to have small diameter capillary bores, if the wick support element 120 is thin enough.

In the arrangements of FIGS. 95 to 102, the position of the wick 111 is precisely determined, relative to the casing 300, either because the wick support element is part of the casing itself, as in the arrangement of FIG. 102, or because the position of the wick support element 720 is determined by a component of the casing such as the tube 302, as in the arrangement of FIGS. 103 and 104. This precise positioning of the wick 111 in the casing 300 means that manufacture will be consistent and hence replacement of one consumable with another will not alter the relationship between the wick 111 and the heater 112, and so will not affect the efficiency of the smoking substitute device.

The use of capillary bores 122 in the wick support element 720 in the arrangements of FIGS. 102 to 104 mean that it is possible to optimize the flow of aerosol precursor to the wick 111 to minimize leakage.

The length and diameter of the capillary bores 122 may be chosen to control the flow of a specific aerosol precursor formulation to the wick 111, based on the viscosity and liquid characteristics of that aerosol precursor. When aerosol precursor is vaporized from the wick 111 by the heater 112, there will be an available volume of air in the wick 111 allowing additional aerosol precursor to flow into the wick 111, so that the wick 111 is maintained in a saturated state when the device is in use. The rigid nature of the wick support element 720 improves the consistency of liquid flow to the wick 111, compared to a wick support element 120 of resilient material, so that efficient operation may be achieved. The sealing configuration in the arrangement of FIGS. 103 and 104 makes use of O-rings, with the effect of minimizing leakage in use and in transit, as a robust seal is created between the wick support element 720 and the casing 300, so that there is no leakage path therebetween. O-ring technology is well established, so it is straight forward to put in to practice in the smoking substitute device to reduce or eliminate variation between parts, improving repeatability of manufacture. The use of a rigid wick support element 720 in the arrangements of FIGS. 102 to 104 means that the wick support element 720 is easy to manufacture with high precision, and the assembly of the consumable may easily be automated. This ensures efficient manufacture, thereby reducing costs.

The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilized for realizing the disclosure in diverse forms thereof.

While the disclosure has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the disclosure set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the disclosure.

For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.

Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

Throughout this specification, including the claims which follow, unless the context requires otherwise, the words “have”, “comprise”, and “include”, and variations such as “having”, “comprises”, “comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” in relation to a numerical value is optional and means, for example, +/−10%.

The words “preferred” and “preferably” are used herein refer to embodiments of the disclosure that may provide certain benefits under some circumstances. It is to be appreciated, however, that other embodiments may also be preferred under the same or different circumstances. The recitation of one or more preferred embodiments therefore does not mean or imply that other embodiments are not useful and is not intended to exclude other embodiments from the scope of the disclosure, or from the scope of the claims. 

1. A fluid-transfer article comprising a first region for holding an aerosol precursor and for transferring said aerosol precursor to an activation surface of a second region of said article, said activation surface being disposed at an end of said article configured for thermal interaction with a heater of an aerosol-generation apparatus, wherein said second region is a flexible diaphragm.
 2. A fluid-transfer article according to claim 1, wherein said flexible diaphragm is formed from a polymeric wicking material.
 3. A fluid-transfer article according to claim 2, wherein said polymeric wicking material comprises Polyetherimide (PEI).
 4. A fluid-transfer article according to claim 2, wherein said polymeric wicking material comprises Polyether ether ketone (PEEK).
 5. A fluid-transfer article according to claim 2, wherein said polymeric wicking material comprises Polytetrafluoroethylene (PTFE).
 6. A fluid-transfer according to claim 2, wherein said polymeric wicking material comprises Polyimide (PI).
 7. A fluid-transfer article according to claim 2, wherein said polymeric wicking material comprises Polyethersylphone (PES).
 8. A fluid-transfer article according to claim 2, wherein said polymeric wicking material comprises Ultra-High Molecular Weight Polyethylene (UHMWPE).
 9. A fluid-transfer article according to claim 2, wherein said polymeric wicking material comprises Polypropylene (PP).
 10. A fluid-transfer article according to claim 2, wherein said polymeric wicking material comprises Polyethylene Terephthalate (PET).
 11. A fluid-transfer article according to claim 2, wherein said polymeric wicking material is porous.
 12. An aerosol-generation apparatus comprising a heater and a fluid-transfer article comprising a first region for holding an aerosol precursor and for transferring said aerosol precursor to an activation surface of a second region of said article, said activation surface being disposed at an end of said article configured for thermal interaction with the heater, wherein said second region is a flexible diaphragm.
 13. An aerosol-generation apparatus according to claim 12, wherein said flexible diaphragm is arranged to be movable between a first position in which a part of said flexible diaphragm is in contact with said heater, and a second position in which said part of said flexible diaphragm is spaced from said heater.
 14. An aerosol-generation apparatus according to claim 13, wherein said flexible diaphragm is biased towards said first position.
 15. An aerosol delivery system comprising: an aerosol-generation apparatus comprising a heater and a fluid-transfer article comprising a first region for holding an aerosol precursor and for transferring said aerosol precursor to an activation surface of a second region of said article, said activation surface being disposed at an end of said article configured for thermal interaction with the heater, wherein said second region is a flexible diaphragm; and a carrier comprising housing containing said heater and said fluid-transfer article, said housing having an inlet and an outlet, an air-flow pathway being defined between said inlet and said outlet, said air-flow pathway passing between said flexible diaphragm and said heater, said air-flow pathway being obstructed when said flexible diaphragm is in said first position. 16.-106. (canceled) 